Systems, methods, and devices for commissioning wireless sensors

ABSTRACT

In one embodiment the present invention comprises a smartphone and encoders for commissioning RFID transponders. The present invention further includes novel systems, devices, and methods for commissioning RFID transponders with unique object class instance numbers without requiring a realtime connection to a serialization database.

RELATED APPLICATIONS

The present application is a continuation-in-part application based onU.S. patent application Ser. No. 12/820,109 filed on 21 Jun. 2010, nowU.S. Pat. No. 8,228,198, which claims benefit claims benefit under 35USC Section 119(e) which is a continuation-in-part application based onU.S. patent application Ser. No. 11/465,712 (U.S. Pat. No. 7,830,258)filed on 18 Aug. 2006, which claims benefit under 35 USC Section 119(e)of U.S. Patent Application No. 60/709,713 filed on 19 Aug. 2005, and acontinuation-in-part of U.S. patent application Ser. No. 12/124,768(abandoned) filed on 21 May 2008, which claims benefit claims benefitunder 35 USC Section 119(e) of U.S. Provisional Patent App. No.60/939,603 filed on 22 May 2007, all by the same inventor Clarke W.McAllister. The present application is based on and claims priority fromthese applications, the disclosures of which are hereby expresslyincorporated herein by reference.

BACKGROUND

The present invention relates to a system, including methods anddevices, utilizing wireless sensor devices and RFID (radio-frequencyidentification) transponders. Specifically, the present inventionrelates to a system incorporating novel devices and methods that enablepoint-of-use and on-demand commissioning of RFID transponder-equippedwireless sensors.

Radio-frequency identification (RFID) transponders enable improvedidentification and tracking of objects by encoding data electronicallyin a compact tag or label. And, advantageously, the compact tag or labeldoes not need external, optically recognizable or human-readablemarkings. In fact, using the Gen2 EPC specification, a three-meterread-distance for RFID transponders is common—even on high-speedmaterial handling lines.

Radio-frequency identification (RFID) transponders, typically thintransceivers that include an integrated circuit chip having radiofrequency circuits, control logic, memory and an antenna structuremounted on a supporting substrate, enable vast amounts of information tobe encoded and stored and have unique identification. Commissioning, theprocess of encoding specific information (for example, data representingan object identifier, the date-code, batch, customer name, origin,destination, quantity, and items) associated with an object (forexample, a shipping container), associates a specific object with aunique RFID transponder. The commissioned transponder responds to codedRF signals and, therefore, readily can be interrogated by externaldevices to reveal the data associated with the transponder.

Current classes of RFID transponders rank into two primary categories:active RFID transponders and passive RFID transponders. Active RFIDtransponders include an integrated power source capable ofself-generating signals, which may be used by other, remote readingdevices to interpret the data associated with the transponder. Activetransponders include batteries and, historically, are consideredconsiderably more expensive than passive RFID transponders. Passive RFIDtransponders backscatter incident RF energy to specially designed remotedevices such as interrogators.

Combining the benefits of the latest technology in RFID transponderswith sensing devices, a broader class of devices called wireless sensorsis emerging. Wireless sensors have a unique identity, sense one or moreattributes within its environment, and report its identity and datacorresponding to the sensed attributes. For example, a wireless sensorinterprets environmental conditions such as temperature, moisture,sunlight, seismic activity, biological, chemical or nuclear materials,specific molecules, shock, vibration, location, or other environmentalparameters. Wireless sensors are distributed nodes of computing networksthat are interconnected by wired and wireless interfaces.

Wireless sensors, made using silicon circuits, polymer circuits, opticalmodulation indicia, an encoded quartz crystal diode, or Surface AcousticWave (SAW) materials to affect radio frequency or other signalingmethods, communicate wirelessly to other devices. For example, certainembodiments of wireless sensors communicate on a peer-to-peer basis toan interrogator or a mobile computer. Communication methods includenarrow band, wide band, ultra wide band, or other means of radio orsignal propagation methods.

Generating a unique serial number is imperative, and is required forEPCglobal RFID tagging implementations. Serialization requires a centralissuing authority of numbers for manufacturers, products, and items toguarantee uniqueness and to avoid duplication of numbers. Blocks ofnumbers are distributed to remote locations globally. Unless a product(or SKU) is serialized at one location, the numbering space is usuallypartitioned according to some method, or each remote location receiveseach number one-by-one. Either way, there is eventually a reconciliationof serial number usage with a granularity of either one or severalnumbers at a time.

A preferred method of generating unique serial numbers is to assignunique numbers in a central location, such as in a label converterfacility where unique bar coded labels are printed. Each unique label isthen packed and shipped to remote locations, usually either in sheets orrolls. Upon arrival at a manufacturing facility, rolls are loaded ontohigh speed label applicators that apply one serialized label onto eachcarton. As those serialized cartons move through the supply chain, theymay eventually arrive at a case pick location, a receiving dock, orsimilar location where a serialized carton is selected for having anRFID transponder applied to it. Using a bar code scanner to read one ormore bar codes sufficient information can be collected to uniquelyencode that data into an RFID transponder and apply it to that carton.

The uniqueness of an identifier is critical to the success of almost anytracking system. Assuring uniqueness is not necessarily simple. Agenerically descriptive bar code can be matched to authorizations forselected numbering systems that provide additional data fields includinga unique serial number or using algorithms that assure uniquenessthrough numerical representations of time and space.

Certain prior art systems use printer encoders to merge the printing andRFID transponder encoding operations into a single atomic transaction.This method is more expensive in every respect. It requires mobiledistributed printing with nearly perfect networking implementations inorder to achieve a smooth, easy, and regular manual transponderapplication process. This all comes at a higher price, size, and weight.Prior art implementations tend not to be mobile, as represented by U.S.Pat. No. 7,066,667 issued to Chapman et al. on 27 Jun. 2006 and includeU.S. Pat. No. 5,899,476 issued to Barrus et al. on 31 May 2005, or byU.S. Pat. No. 6,246,326 issued to Wiklof et al. on 12 Jun. 2001,describe a device that commissions an RFID transponder with a printedlabel. This approach, however, introduces unnecessary waste, cost, andpropensities for error. There is a growing category of applications thatdo not require anything other than a custom-encoded RFID transponder.This prior art calls for the inclusion of label printer hardware andrelated consumable materials that are not necessary for many RFIDapplications. Unneeded printer mechanisms create unnecessarycomplexities, size, and weight. In some instances this additional bulkhinders practical mobile applications. The result is that taggingsolutions that include printing result in a higher total cost ofownership than a pure RF tag encoding system.

So, despite recent advances in RFID technology, the state-of-the-artdoes not fully address the needs of simple, efficient, economical,high-volume, reliable deployment and commissioning of RFID transpondersand wireless sensors. Large-scale adoption of RFID transponders dependson systems utilizing reliable, low-cost transponders deployed atthousands of distributed locations that implement simple and efficientmanual transponder commissioning means. Such systems should furtherinclude processes for efficient commissioning of batches of RFIDtransponders, without the need for realtime wireless connectivity.

SUMMARY OF THE INVENTION

The present invention overcomes the shortcomings of the prior-artattempts and, accordingly, provides systems, methods, and devices thatcommission RFID transponders on-demand and at a point-of-use utilizingwireless data transfer in a compact package that is well-suited toportable, mobile, or fixed use in multiple applications. The presentinvention is used for reading data from or encoding data onto wirelesstransponder data carriers with no external authorizations or queriesrequired on a transponder-by-transponder basis. Additionally thisinvention teaches a preferred method and apparatus for commissioningRFID transponders without requiring continuous use of a screen or keypadto control operations. Further advantages of the present invention willbe well-appreciated by those skilled in the art upon reading thisdisclosure including the appended figures of the drawing.

Authorizations for one or more classes of objects are preferably loadedinto the encoder; where such authorizations include data fields such asmanufacturer ID, item reference, manufacturer code lengths, filtervalues (that designate packaging levels such as item, case, pallet,etc.), serial number starting point for a block, and otherpre-determined parameters. Such information is preferably loaded intothe memory of the encoder in advance of tag commissioning operations.Thus if loaded with information for more than one object class, theencoder does not have sufficient information to proceed with encoding atransponder until a single object class is selected for the present RFIDtransponder to receive; an ambiguity therefore exists that is preferablyresolved with information entered by an operator using either a keypador a bar code scanner. Reading printed indicia such as a bar code is apreferred method to resolve the ambiguity as to which object class thenext RFID transponder is to receive a number from. Bar codes are used toeliminate errors and ambiguities that enable the encoder to locallygenerate or replicate data for encoding into a data carrier such as anRFID transponder.

This type of data production and/or replication process is very fast andefficient. There is no absolute need to query a database in real time;hence there is no need for continuous wireless network connectivity.This simplification eliminates the possibilities for non-deterministicnetwork delays. Non-deterministic delays are delays that cannot beguaranteed, usually due to the probabilistic nature of packet collisionsthat are common in Ethernet and WiFi. By eliminating the need to accessa network database, the variable non-deterministic delays caused bychanging database sizes, changing record counts, and database user loadfluctuations are completely circumvented. Reduction or outrightelimination of non-deterministic delays helps manual labor operate atmaximum efficiency, allowing them to achieve a regular and dependablecadence in their transponder application processes.

For example, in one embodiment the present invention consists of anencoder for commissioning RFID transponders. The encoder consists of anRFID interrogator module adapted to enable encoding predetermined dataaccording to a commissioning algorithm and communicating with aninternal antenna, the antenna being adapted to encode the predetermineddata on the RFID transponder; a memory storage device for storing atleast a portion of the predetermined data; a processing means forcontrolling and communicating with the memory storage device, the RFIDinterrogator and the internal antenna; a means for providing a supply ofRFID transponders, the transponders configured for tensile extractionfrom the encoder or, preferably from means for providing a supply ofRFID transponders comprising a cartridge; and a means for presenting theRFID transponder within an operable range of the internal antenna ornear field coupler to enable encoding of the predetermined data.

In further embodiments, the present invention includes a method forcommissioning RFID transponders comprising: providing a roll or sheet ofRFID transponders; providing a cartridge or other pre-packagedself-contained supply of RFID transponders; providing an encoder;inserting the roll or sheet in the cartridge or other pre-packagedself-contained supply of RFID transponders; coupling the cartridge tothe encoder; acquiring information to encode from printed indicia;encoding the information on at least one RFID transponder; and adaptingthe process of attachment of the encoded transponder to the targetsurface along a vector that is nearly parallel to the target surfacebased upon real time feedback from the surrounding environment.

DRAWINGS

FIG. 1 is a block diagram of the system and environment according to oneembodiment of the present invention.

FIG. 2 is a top view of a possible RFID transponder according to oneembodiment of the present invention.

FIG. 3 is a schematic end-view of the RFID transponder of FIG. 2.

FIG. 4 is a top view schematic drawing of a sheet or roll of a pluralityof RFID transponders of FIG. 3.

FIG. 5 is an offset orthogonal view of a mobile encoder according to oneembodiment of the present invention.

FIG. 6 is a schematic block diagram showing some components of themobile encoder of FIG. 5.

FIG. 7 is a schematic cross section view showing electro-mechanicalcomponents of one embodiment of a mobile encoder.

FIG. 8 is a schematic cross section of an encoder according to thepresent invention.

FIG. 9 is a frontal-offset view of a hand-held, mobile encoder accordingto the present invention.

FIG. 10 is a schematic cross section of another encoder according to thepresent invention.

FIG. 11 is a flow chart of a smartphone scan and transponder encodemethod according to the present invention.

FIG. 12 is a flow chart of a tagging method according to the presentinvention.

FIG. 13 is a flow chart of a commissioning method according to thepresent invention.

FIG. 14 is a diagram of a serialization method according to the presentinvention.

FIG. 15 is a system block diagram according to the present invention.

FIG. 16 is a flow chart of a biometric authentication method accordingto the present invention.

FIG. 17 is a block diagram of the system and environment according toone embodiment of the present invention.

FIG. 18 is a top view of a possible RFID transponder according to oneembodiment of the present invention.

FIG. 19 is a material stack specification of an RFID transponderaccording to one embodiment of the present invention.

FIG. 20 is a side view of a web of release liner containing RFIDtransponders, provided on a source roll, stretched tight around a peeldevice, and advanced forward onto a take-up reel according to oneembodiment of the present invention.

FIG. 21 is a side view of a handheld mobile encoder with an integratedbar code scanner according to one embodiment of the present invention.

FIG. 22 is a diagram of a smartphone with FIPS 140-2 module and nearfield couplers according to one embodiment of the present invention.

FIG. 23 is a flow chart of a first method according to the presentinvention.

DESCRIPTION OF THE INVENTION

Making reference to various figures of the drawing, possible embodimentsof the present invention are described and those skilled in the art willunderstand that alternative configurations and combinations ofcomponents may be substituted without subtracting from the invention.Also, in some figures certain components are omitted to more clearlyillustrate the invention. In some figures similar features share commonreference numbers.

To clarify certain aspects of the present invention, certain embodimentsare described in a possible environment—as identification means forcontainers. In these instances, certain methods make reference tocontainers such as loaded pallets, paperboard boxes, corrugated cartons,pharmaceutical containers, and conveyable cases, but other containersmay be used by these methods. Certain embodiments of the presentinvention are directed for use with steel drums, commercial corrugatedshipping cartons, tagged pallet-loads of shrink-wrapped cases,consumer-goods packaging, consumer goods, automobile windshields,industrial components, or other methods of identifying objects usingRFID transponders or wireless sensors, or both. In certain embodimentsthe target surface to which a transponder will be attached is acontainer. In some applications the target surface is moving while theencoder device is stationary. Furthermore the moving target surface maybe objects on a conveyor. In yet other embodiments the target surfacemay be a web of release liner from which encoded transponders will belater removed and applied to an object for identification.

Some terms are used interchangeably as a convenience and, accordingly,are not intended as a limitation. For example, transponders is a termfor wireless sensors that is often used interchangeably with the termtags and the term inlay, which is used interchangeably with inlet. Thisdocument generally uses the term tag or RF tag to refer to passive inlaytransponders, which do not include a battery, but include an antennastructure coupled to an RFID chip to form an inlay which is generallythin and flat and substantially co-planar and may be constructed on topof a layer of foam standoff, a dielectric material, or a foldedsubstrate. One common type of passive inlay transponder further includesa pressure-sensitive adhesive backing positioned opposite an inlaycarrier layer. However, certain aspects of the present invention workequally well with active inlay transponders. A third type: abattery-assist tag is a hybrid RFID transponder that uses a battery topower the RFID chip and a backscatter return link to the interrogator.Further, this document uses programmable RFID transpondersinterchangeably with RFID transponders. Programmable transponders enabledata to be written or stored more than once.

Suitable environments or applications for certain aspects of the presentinvention include: traditional conveyor line or other high-speedmachinery with automated transponder printing, encoding, and attachment;hand attachment of transponders (a method that often is referred to as“slap and ship”); and a novel category of mobile transponder encoders(as will be more fully described herein); shipside receiving ofautomobiles; case picking operations that include selective taggingprocess steps; and receiving untagged cartons into an RFID-enabledretail store or a manufacturing plant.

The systems, methods, and devices of the present invention utilize anRFID transponder or wireless sensors as a component. Certain RFIDtransponders and wireless sensors operate at Low Frequencies (LF), HighFrequencies (HF), Ultra High Frequencies (UHF), and microwavefrequencies. HF is the band of the electromagnetic spectrum that iscentered around 13.56 MHz. UHF for RFID applications spans globally fromabout 860 MHz to 960 MHz. Transponders and tags responsive to thesefrequency bands generally have some form of antenna. For LF or HF thereis typically an inductive loop. For UHF there is often an inductiveelement and one or more dipoles or a microstrip patch or othermicrostrip elements in their antenna structure. Such RFID transpondersand wireless sensors utilize any range of possible modulation schemesincluding: amplitude modulation, amplitude shift keying (ASK),double-sideband ASK, phase-shift keying, phase-reversal ASK,frequency-shift keying (FSK), phase jitter modulation, time-divisionmultiplexing (TDM), or Ultra Wide Band (UWB) method of transmittingradio pulses across a very wide spectrum of frequencies spanning severalgigahertz of bandwidth. Modulation techniques may also include the useof Orthogonal Frequency Division Multiplexing (OFDM) to derive superiordata encoding and data recovery from low power radio signals. OFDM andUWB provide a robust radio link in RF noisy or multi-path environmentsand improved performance through and around RF absorbing or reflectingmaterials compared to narrowband, spread spectrum, or frequency-hoppingradio systems. Wireless sensors are reused according to certain methodsdisclosed herein. UWB wireless sensors may be combined with narrowband,spread spectrum, or frequency-hopping inlays or wireless sensors.

System and Encoder Overview

Referring to FIG. 1 the present invention includes a system forcommissioning wireless sensors at a point of use and on-demand. Forexample, in one embodiment, the present invention incorporates a mobileencoder device 30, which may be attached to a belt of an operator andpowered by rechargeable batteries 60. The mobile encoder is in wirelesscommunication with a remotely located host computer. The operator canselectively (on-demand) enable the mobile encoder to commission atransponder based on various criteria, including input received from amobile bar code scanner, for example.

FIG. 1 shows one system 10 according to the present invention in atypical environment, such as a packaging facility wherein a collectionof entities with visual external labels 15 exist and a sub-set (or allentities) need to be associated with a wireless RFID transponder, tag,or label. The object 17 needing an RFID transponder could be a packingcontainer having an assorted collection of entities 15. As entities 15are pulled from collection 176, a traditional optical reader 13 (humanor machine) interprets the visual external label. Information from theexternal, visual label is correlated to information stored in acentralized location, represented by a network computer 11 having adatabase. The information taken by the optical reader 13 is transmittedto the network computer 11. System 10 includes a wireless connectionbetween the remote computer 20 and the mobile encoder 30 either directlyor through a common wireless access point. Additionally, a wirelessconnection could occur between the remote computer 20 and the hostcomputer 11, and in this embodiment, the remote computer 20 is inphysical connection with the mobile encoder. In yet another embodiment,the remote computer 20 wirelessly connects to both the mobile encoder 30and the host computer 11. Optionally, the optical reader 13 can beincorporated in the encoder 30.

Referring to FIGS. 3 and 4, in further embodiments, the presentinvention incorporates a mobile encoder device 175, 30, or 220 which maybe held in the hand of an operator. Mobile encoder device 175, 30, or220 is preferably powered by rechargeable batteries or a fuel cell.System 170 includes at least four possible intermittently connectedentities if they are present and connected: mobile encoder 175, remotecomputer or mobile phone 154, optical reader 173, and headset 174. Apreferred short range wireless connection means 175A such as a WLAN(Wireless Local Area Network) or PAN (Personal Area Network) may beestablished from time to time between mobile encoder 175 and remotecomputer or mobile phone 154, optical reader 173, and/or headset 174.There is a preference for low power wireless connection apparatus withinmobile encoder 175 so as to realize the greatest possible battery lifein light weight mobile encoder 175. Mobile encoder 175, 30, or 220 is inintermittent wireless communication with a mobile phone or computer 154typically at close range through wireless communication means 175A.Database and associated host computer 171 may be housed at a remotelylocated facility that may optionally be accessed over a large distancethrough remote computer or mobile phone 154. A mobile phone is apreferred bridge between two or more wireless networks, for example aPAN and a wireless subscriber network that supports wireless dataservices for ultra mobile and remote tagging applications. Continuouswireless connection to a host database is not required for ongoing tagcommissioning process steps disclosed herein.

RFID tags such as those using EPCglobal numbers requires uniqueness ofthe numbers that are encoded. GS1 is a central authority that prescribesa set of hierarchies for each key type (type of identity such as anSGTIN) whereby GS1 designates itself as the central issuing authorityfor each key type. Authority is passed down in a hierarchical manner tomember companies. Each member company has the authority to furtherallocate numbers from its upper level database to as many lower databaselevels as it deems necessary to distribute number authority throughoutits enterprise.

Quasi-autonomous RFID transponder encoding authority is achieved when anexternal number issuance authority allocates to the encoder blocks ofnumbers for specific object classes. A preferred embodiment forquasi-autonomous transponder encoding authority is realized when largepre-authorized blocks of serial numbers are made available to encoder175 or 30 to utilize on object classes as objects of a class arepresented for tagging. A preferred method of providing pre-authorizedblocks of object class serial numbers is to subdivide the entire objectclass serial number space into sectors that are defined by a limitednumber of MSB's (Most Significant Bits) of the serial number field. Theobject class serial number space is defined by the number of serialnumber bits that are used in a specific standard, such as a particularEPCglobal key type, for example an SGTIN-96 and is defined in acorresponding specification such as the GS1 EPCglobal EPC Tag DataStandard. Again using the SGTIN-96 as an example, there are a total of38 bits used to define the entire serial number space which contains 2³⁸unique numbers. For example the upper 14 bits could be designated as themost significant bits for a particular embodiment. In that case theobject class serial number space would be comprised of 16,384 sectors.Since in this example there are 14 most significant bits within a 38 bitserial number field, there must be 38 minus 14 bits of lessersignificance, which equals 24 bits. Therefore the lower 24 bitsrepresent 16,777,216 unique serial number values. Once a sector isallocated to a lower level within an authority hierarchy, it is referredto as a block. Each allocated block of serial numbers representsauthority for encoding objects of an object class that can either beused by an encoder for encoding transponders, or allocated to a lowerlevel in the authority hierarchy.

In a preferred embodiment serial number block sizes are sufficient tooperate encoder 175 or 30 for extended periods of time without anyfurther external authorization steps. For example autonomous operationfor a week or more is possible with sufficiently large block sizes. Inthe previous example the encoder could encode over 16 million objects ofan object class without the need to reconnect with a higher levelauthority. If 10,000 objects of an object class are encoded each day,then the encoder could operate in a quasi-autonomous mode for up to 1677days or over four years without receiving further authorizations from ahigher level authority. Block allocations are preferably assigned withreference to how many encoders 175 or 30 are authorized to operatewithin the facilities of the owner of certain object class numbers.

Authorizations for one or more classes of objects are preferably loadedinto encoder 175, 30, or 220 from an external authority where suchauthorizations include data fields such as manufacturer ID, itemreference, manufacturer code lengths, filter values (that designatepackaging levels such as item, case, pallet, etc.), serial numberstarting point for a block, and other pre-determined parameters. Suchinformation is preferably loaded into the memory of the encoder inadvance of tag commissioning operations. Thus if loaded with informationfor more than one object class, encoder 175, 30, or 220 does not havesufficient information to proceed with encoding a transponder until asingle object class is selected for the present RFID transponder toreceive; an ambiguity therefore exists that is preferably resolved withinformation entered by an operator using either a keypad or a bar codescanner. Reading printed indicia such as a bar code is a preferredmethod to resolve the ambiguity as to which object class the next RFIDtransponder is to receive a number from. Bar codes are used to eliminateerrors and ambiguities that enable encoder 175, 30, or 220 to locallygenerate or replicate data for encoding into a data carrier such as anRFID transponder.

GS1 is a leading global organization dedicated to the design andimplementation of global standards and solutions to improve theefficiency and visibility of supply and demand chains. GS1 definesEPCglobal SGTIN number fields as having a company prefix, an itemreference, a partition value, and a filter value that comprise theobject class information. A unique serial number is then added to thatinformation to create each unique instance within each object class.

In a preferred embodiment, a block is allocated and managed using threenumbers: a starting number that is the first serialized instance of ablock, a block size which represents the total number of instances inthe block, and a counter or index that represents how much of the blockhas been used during an encoding process. Using these three numbers andan optional lock bit, a simple database of object class authorizationscan be built.

A preferred embodiment utilizes RFID authorization transponder 178A anda printed substrate 1786 to physically handle object class serial numberissuance authorizations. Authorization transponder 178A is interrogatedby transponder reading/encoding means 175H. Preferred embodiments usethe 96-bit EPC memory bank for specifying the block starting number,including the company prefix, item reference, partition value, filtervalue, and base serial number. The User Memory bank is used to hold andtransfer the block size (preferably 16-bits), counter or index value(preferably 16-bits), a 16-bit header to identify the transponder as avalid member of a class of authorization transponder, a lock bit, and aCRC value to detect errors in all of the data fields. For example a CRCerror would detect errors in storage, transponder selection, or datatransmission. In preferred embodiments reading of data blocks from morethan one RFID transponder would be avoided by selecting a transponder,checking that it is the correct type, contains valid authorization data,contains a valid header that signifies that it is an RFID authorizationtransponder 178A, and that all data read correctly verifies with adedicated error detection field such as a CRC.

RFID authorization transponder 178A is preferably adhered to printedsubstrate 178B so that an operator can visually identify what objectclass or SKU is managed by the affixed authorization transponder 178A. Apicture, icon, bar code, or human readable symbols are all useful foridentifying the object class. An operator presses a button or scans abar code that prompts encoder 175 to read and store the taggingauthorization held by authorization transponder 178A. Once read,authorization transponder 178A is preferably electronically marked as‘consumed’ or ‘locked’ by transponder encoding means 175H. EPCtransponder ID fields that identify a specific type of chip arepreferred for selecting the proper transponder, even when other RFIDtransponders are within range of the antenna or near field coupler oftransponder encoding means 175H.

A collection of authorization transponders 178A comprises a databasethat can be physically transported without the need for a wirelesscommunications link to encoder 175. Once read, database records arepreferably stored in internal memory means 175G. In a preferredembodiment 12 to 14 bytes of Flash memory is used for each record toallocate 250 to 65536 instances of an object class, whereby the firstbyte of an EPC number is a fixed header value can be replaced in Flashmemory by 8 bits of the allowable block size. One or two bytes in RAMare used to count or index through the block allocation as it is used.Thousands of data records of this type can easily fit into the memoryspace of an economical 8-bit microcontroller. In a preferred embodiment,where the GS1 SGTIN-96 header is replaced in memory with an 8-bit blocksize authorization, 300 records for authorizing up to 255 instances perrecord, can be used to safely manage at least 500,000 tagging recordsusing 24,000 bytes of Flash memory and 2000 bytes of RAM. Otherembodiments using more bits to authorize and control larger blocks ofnumbers is possible at a slightly larger expense of memory.

A preferred embodiment uses a computer, preferably a smartphone such asan iPhone from Apple Inc. of Cupertino, Calif. as a lower database levelto transfer encoding authorizations from upper level databaseauthorities to RFID encoders. A smartphone such as the iPhone or anAndroid phone using software from Google would be a preferred embodimentof a lower database level and or an encoder using an antenna or nearfield coupler similar to near field coupler 224A2 of FIG. 21 or 238 a or238 b of FIG. 22 to couple with RFID transponders for encoding andverification. The iPhone also has cellular data transmission radios andsoftware stack to enable the iPhone to access remotely located serversin a cloud computing architecture.

The smartphone establishes a connection with a cloud-based server usingJavaScript, ASP, JSP, PHP, Perl, Tcl or Python scripts to access adatabase such as mySQL that is available from Oracle Corporation ofRedwood Shores, Calif. Using structured query language, SQL databasetables are preferably used to store tag commissioning data,configuration information, and serial number block allocation records.SQL queries provide information from database tables to the script,passing the result over the Internet, to the smartphone, which also thenroutes information to designated RFID encoders. Encoders are preferablyidentified by their media access control (MAC) address or a UUID whichis guaranteed to be unique and is used by the smartphone as a lowerdatabase level to transfer encoding authorization to a specific encoder.

Preferred embodiments of encoder 175, 30, or 220 will encode all of theGS1 identity types. Such types include the General Identifier (GID-96),Serialized Global Trade Item Number (SGTIN), Serial Shipping ContainerCode (SSCC), Serialized Global Location Number (SGLN), Global ReturnableAsset Identifier (GRAI), and the Global Individual Asset Identifier(GIAI). Other preferred embodiments are used to encode numbers that area part of other numbering systems.

Data records are preferably loaded and stored through commands that aretransmitted over wireless communication means 175A. In preferredembodiments, batch mode commands can be used in any of three ways: (1)to immediately affect the current operation by starting a batch taggingprocess for a specified SKU or object class; (2) to store authorizationsin memory means 175G; and (3) to store authorizations in stored-valueRFID transponder 178A.

When external connection is necessary, wired or wireless communicationwith an external host or numbering authority is established. Wirelesscommunication means 175A is preferably a Wi-Fi or Bluetooth connection.A wireless node of a Bluetooth personal area network is used accordingone embodiment of the present invention. Model 100-SER manufactured byEmbeddedBlue of Poway, Calif. and the BISMS02 from EZURiO Ltd., asubsidiary of Laird Technologies, Inc. of Chesterfield, Mo. are examplesof preferred OEM Serial Bluetooth modules. Other wireless interfaces mayalternatively be used to achieve Serial Port Profile and other types ofconnectivity between encoder 175 and remote computer or mobile phone 154and/or optical reader 173.

Other preferred embodiments of mobile encoder 175 and system 170 replacewireless communication means 175A with a cable, resulting in anembodiment of mobile encoder 175 with a tethered bar code scanner. A keyadvantage of an alternative embodiment of system 170 that utilizes awired connection to optical reader 173 instead of wireless communicationmeans 175A is a very simple solution having virtual immunity to anysurrounding RF interference that might raise the noise floor hinderingwireless communications.

The operator can cause mobile encoder 175, 30, or 220 to commission atransponder by scanning certain printed bar code symbols receivedthrough optical reader 173 which is connected to encoder 175 throughwireless communication means 175A. Or alternatively internal opticalreader 175F is used to scan printed bar code symbols. In either casedata from optical reader 173 or 175F is delivered to processing means1756. Certain preferred embodiments of system 170 use optical scannerswith self-contained symbol decoding capabilities to deliver decodedsymbol information to processing means 1756. Certain other embodimentsof system 170 relies on processing means 1756 to conduct some or alldecoding operations to derive information from scanned symbols.

The information derived from the optical reader 173 or 175F is used bymobile encoder 175 to either directly or indirectly encode data into RFtransponder 178 while it is still physically within mobile encoder 175.Mobile encoder 30 uses external optical reader 173, and alternativelymobile encoder 220 uses internal optical reader 175F, as embodied inreader 226 of FIG. 21. Preferred embodiments of optical reader 226 aremechanically aligned relative to transponder encoding means 175H or morespecifically with the antenna or near field coupler of RFID interrogator224A. Spatial alignment assures that an operator will be able tocomfortably scan bar codes and then encode and apply RFID transpondersalong a line of movement such that the operator can easily assure properplacement of encoded transponders.

Symbol decoding functions may be physically, electrically, or logicallyseparated from symbol scanning operations. One preferred embodiment ofoptical reader 173 is a model CHS-7M, CHS-7P, CRS-9M or CRS-9P Bluetoothring scanner.

Processing scanned commands involves a processing step to determine thata bar code should be interpreted as a command or configurationinstructions rather than as bar code 179 that identifies an object thatis to be tagged. Commands are used to alter the flow and operation ofmobile encoder 175.

FIG. 21 is a preferred embodiment of a mobile encoder wherein opticalreader 226 is an OEM bar code scanner manufactured by such companies asIntermec or Motorola and is a preferred embodiment of optional internaloptical reader 175F shown in FIG. 17.

In a preferred embodiment one or more bar codes are pre-printed andapplied as symbol 179 on entity 177 in a manufacturing facility or othersuitable location. Such bar codes are described in ISO/IEC draftdocument PDTR 24729-1 and are more generally referred to as one or morebar codes having Application Identifiers (AI) 01 and 21 encoded intothem, and preferably include header information and other control bitsthat are required for certain protocols. AI 01 is used to represent theStock Keeping Unit (SKU) as a GS1 Global Trade Item Number (GTIN). AI 21is used to serialize the SKU. Together the two AI's are used to specifya GS1 serialized GTIN (SGTIN). Bar codes can also be used to specifydata payloads that use numbering systems other than the EPC numberingsystem. The Application Family Identifier (AFI) also plays an importantrole in designating alternative numbering authorities.

This preferred method that is described by the flow chart in FIG. 23will allow batch mode operation where there are at best intermittentconnections with remote computer 154. This preferred method allowsexisting label application and/or printing hardware located on existingmanufacturing lines to provide in printed symbolic form all data thatwould be encoded into an RF transponder. By providing printed symbols,manufacturers do not have to incur either the cost of that transponderor the special equipment that is required to encode and apply RFtransponders.

Optical reader 173 or 226 is described above and is used as the primarysource of real time data input for the mobile encoding system that usesan embodiment such as mobile encoder 30 or 220. Optical reader 173 or226 is also preferably used to scan special bar codes that instructmobile encoder 175, 30, or 220 to perform certain prescribed functionswhich will be described below.

Certain preferred embodiments of system 170 include headset 174 whichmay be a headset worn by the operator or a Bluetooth-linked loud speakerthat is mounted to a pallet jack or fork lift truck. Headset 174 isoptionally used by system 170 to give instructions, confirmationsignals, or warnings to the operator. Synthesized speech or audibletones are used to interact with the operator through headset 174.

In these aforementioned embodiments, the mobile encoder 30 is a portabledevice that can be easily mounted in a fixed location, carried such asmobile encoder 220, or worn by a human operator such as mobile encoder30, or hung from a suspended retractable tool cable. As such, the mobileencoder 30 includes an internal power source 175E such as a rechargeablelithium-ion battery and would further include a handle or a belt-clipfor ease of use. In another embodiment, the mobile encoder can beattached to a high-speed conveyor line. In such an application, theon-board battery could be replaced or augmented by a physical connectionto a remote power source. Further, the computer 20 could have wiredconnects to the host network 11. Further details of possibleconfigurations of the mobile encoder will be further detailed insubsequent sections of this disclosure.

In the system 10 of FIG. 1, the mobile encoder 30 carries a supply ofun-commissioned (or blank), or securely encodable RFID transponders175J, 185, 42, or 221E. Once the desired data is accumulated andpresented to the encoder 30 from the computer 20, the encodercommissions an RFID transponder, using transponder transport means 175Cand transponder encoding means 175H and any one of several preferredencoding algorithms to program, creating an RFID tag or label 50 for theobject 177. Transponder separation means 175D is used to separate aproperly encoded transponder 178 from release liner conveyance web 182by breaking the bond at adhesive layer 181D on the leading edge oftransponder 178. Transponder separation means 175D is preferably a peeldevice 183 as shown in FIG. 20 or peel device 222B in mobile encoder220. Peel devices 183 or 222B are preferably made from anti-staticplastic, metal, or other material that will conduct electrostatic chargeaway from transponder 178 and release liner 182. The commissioned tag orlabel 50 can then be applied, linked, or otherwise associated with theobject by known means including a human operator or a machine transfer.

RFID Transponders

FIG. 2 shows a preferred embodiment of an RFID transponder 50. RFIDtransponders, in some embodiments, comprise an RFID integrated circuit(IC) device (or “chip”) 56 of FIG. 3 or 180 of FIG. 18 bonded to anantenna apparatus, formed on a substrate that is often plastic such asMylar®, polyester, or PET. One way to form an antenna structure is toetch copper from a substrate. An alternate printed transponder includesprinting multiple layers of conductive ink onto a substrate. Oneadditional method includes stamping UHF antennae from thin sheets ofaluminum, or by selective aluminum deposition onto a substrate. Incertain embodiments, RFID transponders and wireless sensors arerecovered from waste streams for reconditioning, reprogramming, andreuse.

Other suitable RFID transponders include designs that combine adielectric spacer behind the antenna by separating the metallic antennainlay 181C from surrounding metals that may detune it, or liquids thatmay absorb RF energy from it. The dielectric spacer creates atransponder that performs well over a broad range of packagingconditions. The dielectric material is a foam standoff material or anexpanding mechanical structure that provides lift from the target objectand also a more robust design also includes features to protect thetransponder from damage.

In certain embodiments, the RFID transponder is both programmable andmechanically configured for tensile extraction from a protectiveenclosure.

In preferred embodiments, hundreds or thousands of instances of RFIDtransponder 178 are manufactured on a continuous web of flexiblematerial with a spatial separation between them, preferably at regularintervals. Certain preferred embodiments use adhesive-backedtransponders 178 adhered to release liner 182 as shown in FIG. 20, whileother embodiments use the transponder material as its own conveyancethat is severed from the rest of the web at predetermined locations,preferably after encoding and verifying transponder 178 is properlyfunctioning.

In preferred embodiments of the present invention, the face stockmaterial has a physical outline that is not much larger than thephysical outline of the inlay itself. This is in contrast to labelswhich can have at least twice the surface area of the inlay or adirect-printed antenna structure in order to provide space for printedinformation. By having a label outline that is so much larger than theinlay surface area, there are a many possible combinations of inlayplacement within the boundaries of a large printable label. This createsa problem and a challenge for printer/encoders that have to find andlocate an inlay before attempting to encode it. By contrast, the presentinvention uses the detectable optical characteristics of the tag'sminimal physical outline to position the transponder for encoding. Thistransponder positioning method is superior and an improvement over priorart that uses printed label stock as a carrier for RFID inlays whereinthe physical dimensions of printed labels are not in any way a reliableindication of the location of the RFID inlay within the label. This isanother example of how demand label printing further complicates RFIDtransponder encoding.

In one embodiment that is an exception to the minimal outlinetransponder design and positioning method described above, transpondersthat have a very long physical shape can be used to create a loop tosecure an encoded transponder to a tree, a bush, or the handle of apiece of luggage. Preferred embodiments of such transponders are foldedor rolled in order to package them onto a dispensing roll or packagedinto a magazine or cartridge in a fan fold pattern. The resulting bundleof back-and-forth ‘Z’ folded or fan folded face stock material resultsin a compact package that minimizes the amount of release liner thatneeds to be wasted for each tag. Each z-folded transponder is theneasily encoded and dispensed from encoder 175, 30 or 220. Transpondersthat can be encoded, verified, dispensed, and unfolded areadvantageously used in forestry, ornamental nurseries, and airlinebaggage tracking applications where manual tagging is required.

In another embodiment, transponder 178 is pushed out of encoder 175instead of being pulled out through tensile extraction. A transportmechanism for pushing transponders utilizes a gripping method such asfriction or teeth that penetrate the webbing. Although there is a riskof jamming or mutilating the webbing, the advantage is that there is noneed for a release liner to pull the transponder supply through encoder175 using tensile extraction. A preferred ‘tractor feed’ embodimentmitigates the risk of web mutilation by utilizing a regular pattern ofprecut holes along one or both edges of the webbing, into which cogmembers of a drive mechanism engage to advance the webbing. A tractorfeed embodiment is part of Transponder Transport Means 175C of FIG. 17whereby a motor and gear train delivers drive torque to the web throughfriction rollers, penetrating teeth, cogs, or other mechanicalengagement means. In such an embodiment, the preferred transponderseparation means is a web cutter that is used to separate encodedtransponders from unencoded tags. A web cutter can be either active orpassive, in other words cutting force can originate with a motorizedmechanism or with an operator's handling during dispensing andtransponder detachment. A row of plastic or metal saw teeth is apreferred embodiment of a passive transponder separation device.

In another preferred embodiment, transponder 178 is manufactured on ahigh speed press, a bar code is printed onto face stock of transponder178 and information that is representative of that bar coded informationis also encoded into microchip 180. Then encoder 30 or encoder 220preferably read that information from RFID microchip 180 and associateit with a transponder commissioning process that may or may not includethe programming of additional information into RFID microchip 180. Thisis a novel method of reading bar coded information on transponder 178without using a bar code scanner to do so within encoder 30 or 220.

In one embodiment, additional transponder layers include a thin andflexible energy cell comprising two non-toxic, widely-availablecommodities: zinc and manganese dioxide. One suitable energy cell isdeveloped by Power Paper Ltd. of 21 Yegia Kapayim Street, Kiryat Arye,Petah Tikva, P.O.B. 3353, ISRAEL 49130, and incorporates an innovativeprocess that enables the printing of caseless, thin, flexible andenvironment-friendly energy cells on a polymer film substrate, by meansof a simple mass-printing technology and proprietary inks. The cathodeand anode layers are fabricated from proprietary ink-like materials thatcan be printed onto virtually any substrate, including specialty papers.The cathode and anode are produced as different mixes of ink, so thatthe combination of the two creates a 1.5-volt battery that is thin andflexible. Unlike conventional batteries, this type of power source doesnot require casing.

A top layer of an RFID transponder assembly optionally comprises a paperface-stock 181A, which is a very low-cost material but also is the leastenvironmentally resilient. UV-resistant plastic face-stock 181Agenerally provides the best survivability in outdoor and rough-serviceenvironments, and also provides the best protection for the RFIDtransponder assembly.

A bottom layer of pressure-sensitive adhesive (PSA) 181D often is usedfor attachment of transponders to objects and often is referred to as awet inlay or a wet tag or a wet transponder because of adhesion layer181B. Alternatively, a layer of clear, translucent, or opaqueadhesive-backed film or tape is used to attach the transponder orwireless sensor to object or container. The tape, any thin, low cost,flexible material with a self-adhesive backing, such as a conventionalpacking tape, is well-suited for this method of attachment. The tape maybe formed into various shapes to achieve the requirements of thismethod. Certain embodiments may use tape that is preprinted with certainlogos, marks, symbols, bar codes, colors, and designs. Suitableadhesive-backed tape must not—or at least minimally—absorb radiofrequencies within the range of frequencies used by the transponder ortag. The tape material, also, must not corrode the device or otherwisehamper its functionality.

Certain embodiments use a type of packing manufactured specifically fora given encoder. Packing tape can be single-coated pressure-sensitiveadhesive tape or, alternatively, media constructed with multiple layersincluding a backing layer. Certain backing layers are constructed on aplastic film having one or more layers. Certain backing layers are madefrom plastic resins such as polypropylene (PP), polyethylene (PE), orcopolymers of PP, PE, PVC, polyesters, or vinyl acetates. Certainembodiments of PP are mono-axially oriented polypropylene (MOPP),bi-axially oriented polypropylene (BOPP), or sequentially and bi-axiallyoriented polypropylene (SBOPP). Certain backing layers arebiodegradable. Certain backing layers are coated with a pressuresensitive adhesive on one side and a low adhesion release coating on theother side to reduce the amount of power required for the encoder tounroll the tape for application.

FIG. 3 shows a possible embodiment of an RFID transponder 50 that doesnot include an encapsulation layer comprising a separate tape. In thisexample, an adhesive layer 52 bonds with antenna layer 54 that is bondedto inlay substrate layer 58 and integrated circuit 56. Inlay substratelayer 58 and face-stock layer 51 provide resistance againstelectrostatic discharge (ESD) into antenna layer 54 or chip 56.

Other constructions for RFID transponders include one or more additionallayers of high-dielectric material that encapsulate or substantiallycover the inlay. In general, the thicker the dielectric layer the higherthe voltage must be to initiate a flow of electrons through a dielectriclayer. This results in higher ESD voltage ratings. Also, it is wellknown to those skilled in the art that thicker dielectric layers betweenantenna layer 54 and any other metal or liquid also tends to reduceparasitic loading of the antenna whereby maintaining antenna tuning forproper coupling to interrogators within a specified UHF band. In suchembodiments, the integrated circuit chip and antenna bond to an adhesivelayer and are protected from a discharge path through the tape layer byits particular thickness of dielectric material. A second dielectriclayer bonds to the inlay substrate by a second adhesive layer, so that alow voltage discharge path is nonexistent around the two layers of tapesubstrate.

In another possible embodiment of an RFID transponder, the inlaysubstrate provides a second layer of ESD resistance against a dischargepath through an outward-facing tape layer and associated adhesive layer.This construction protects the antenna and chip from electrostaticdischarge originating from any direction. The encapsulation tape layerbonds to the antenna and chip via an adhesive layer and provides noadhesive bond to the transport container when the transponder iscommissioned, and therefore depends on separate adhesive zones to attachto the container of interest.

In another possible embodiment, an RFID transponder includes multiplelayers of ESD resistant material. For example, an outer layer substratebonds to an inner substrate by an intermediate adhesive layer. A secondadhesive layer bonds with the chip and antenna. The inlay substratefaces inward and presses against a transport container when thetransponder is commissioned.

The contemplated adhesives in the various RFID transponder embodimentscreate strong and permanent bonds between tapes and inlay layers over acertain practical range of operating temperatures.

Because RFID transponders are designed to adhere to a container, oneface of an external layer includes a pressure-sensitive adhesive. Thisexternal adhesive, however, must not cause mechanisms associated withthe commissioning devices to jam. To prevent unwanted sticking of theRFID transponder, a transport layer protects the sticky, externaladhesive. The transport layer is either a release liner such as asilicone-treated paper liner or a net (or mesh) web. A net or mesh weboffers two principal advantages: less weight and being recyclable orreusable. A comparison of the weight of a net with a higher percentageof open area to a typical sheet of release liner reveals that thenetting is lighter for any given section of comparable size.Environmental problems of disposal of release liner are well known. Meshor netting, comprised of recyclable resins, is recovered after each useso that the mesh or net can be either reused or recycled for itsconstituent materials.

In one possible embodiment the mesh or netting is made of plastic suchas nylon, polypropylene, polyethylene, HDPE, Teflon, or other resins. Inother embodiments the mesh or netting is fabricated from metal orcarbon-impregnated plastic to provide a conductive path to bleedelectric charge away from points of accumulation.

Other advantages of a net or mesh transport layer include a substantialpercentage of the adhesive not in contact with anything during storageand commissioning. When stored in a roll, a small percentage of theadhesive layer makes contact with the backside of the roll through theopenings in the mesh. Thus, a small amount of energy is required tounroll the spool during transponder commissioning, yet there exists acertain amount of adhesion to prevent a converted spool from unraveling.

In other possible embodiments, the RFID transponders can include asurface suitable for human or machine readable, visible, externalmarkings including bar-code symbols or alpha-numeric sequences.

FIG. 4 shows another embodiment of RFID transponders 50 grouped on sheetstock 59 such as rolls or z-folded sheets that enables a plurality oftransponders to be carried on a continuous web or traditional releaseliner. Other certain embodiments use transponders that are stacked andloaded into magazines for transport, handling, and automated dispensing.In certain embodiments, the magazines contain metallic shielding toprotect transponders and inlays from electrostatic discharges (ESD).

In certain embodiments an RFID encoder is combined with a sensor suite218 as shown in FIG. 10 to enable semi-automated tag application todesired objects. In one embodiment, a semi-automatic encoder/applicatoris created by integrating a single sensor device. The sensor responds tochanges in light, capacitance, pressure, acoustics, or optical pathlength to a transport container. In another embodiment a suite ofsensors are used to detect the attachment location of a commissionabletransponder.

For example, changes in capacitance are detectable using certain QProxcharge transfer capacitance sensors available from Quantum ResearchGroup Ltd. of Hamble, England. Ultrasonic range sensors are availablefrom supplier such as muRata Manufacturing Co., Ltd. of Kyoto Japanunder the trade name Piezotite. Optical path length sensors areavailable from Keyence Corporation of Osaka, Japan. Sharp manufactures acompact distance-measuring sensor GP2D02 that is responsive in the rangefrom 5 to 100 cm. Thus, when a predetermined set of conditions isrealized, the sensor triggers, enables, or selects a desired action. Inone embodiment, proximity or contact of sensor suite with the targetedtransport container causes a second type of Trigger Event, resulting inthe commissioning and dispensing of a transponder by an encoder.

In other embodiments, sensor 218 is designed to determine the distancean encoder resides from an object that is to be tagged. Rangeinformation is acquired and processed in real time to determine if theencoder is in Close Proximity, Near, or Far from a transport container.In certain embodiments a controller is programmed to alter thresholddistances between each range category and to associate a function witheach range. In certain embodiments, range category Close Proximity isassociated with transponder programming and application functions. Forexample, the range category Near is reserved for transponderverification and/or reading functions; and Far is reserved for bar codescanning functions to verify that bar code information aligns properlywith RFID transponder data.

In other embodiments a sensor suite is responsive to certain colors orpatterns and uses that information to instruct the placement or detectthe correct locations for applying good transponders and separatelocations for discharging bad transponders.

FIG. 20 also shows how transponders 178 are rolled onto reels inpreparation for encoding. Source roll 185 contains a supply oftransponders ready for encoding. Release liner 182 conveys transponders178 around peel device 183. Unless transponders 178 are mechanicallyprevented from rotating around peel device 183, they are conveyed ontotake-up roll 184. Take-up reel 184 advances forward while source roll185 lags behind due to drag created by a clutch, brake, motor or otherback-torque generating device. Opposing torques of take-up reel 184 andsource reel 185 result in tension in release liner web 182. Shape memoryin face stock 181A preferably prevents transponder 178 from remainingadhered to release liner 182 as it passes over peel device 183,resulting in the leading edge lifting off and separating from webbing182. If take-up reel 184 continues to advance, and transponder 178 doesnot collide with another object, its attachment to release liner 182 onits trailing edge will result in that transponder being passedcompletely around peel device 183 onto take-up reel 184. Full pathrotation is preferably reserved for transponders that fail to properlyencode desired information; and is therefore intended to be a rejectprocess for failed transponders. Preferred embodiments result in tensioncreated in web 182 in a process of tensile extraction of transpondersfrom a source reel and selective transfer of good transponders onto anobject or a person's finger. Mobile encoder 30 depends on a person'sfinger to prevent transponders 178 from rotating around peel device 183.Mobile encoder 220 depends on a target object such as carton face 228 toprevent transponder 223B from rotating around peel plate 222B on a pathtoward take-up reel 221J.

When the conveyance of RFID transponders results in the positioning of atransponder relative to a near field coupler within a signal null, thetransponder and transport webbing are preferably nudged forward orbackward to improve the signal coupling. This is preferably accomplishedby momentarily activating the motor and transponder transport means175C.

Mobile Encoder

FIG. 17 shows a system 170 according to one embodiment of the presentinvention including a mobile encoder 175. FIG. 5 shows a preferredembodiment for a mobile encoder. Mobile encoder 30 is comprised ofhousing 32, belt clip 34, antenna 36, on/off switch 33, system ready LED37, data ready LED 38, and transponder ready LED 39. It is furthercomprised of auxiliary switch 40, and charger plug 41. A cartridge orother pre-packaged self-contained supply of transponders 42 ispreferably latched, snapped, clicked, popped, inserted, slid, orreleasably mounted to the body of housing 32. The cartridge preferablyincludes a take-up reel 44 for non-dispensed RFID transponders, and aport through which blank or securely encodable transponders emerge fromsource reel 43. The source reel is preferably comprised of a core whichmay be made from plastic or a recyclable kraft paper fiber to form awound tube. A tube extends from the walls of cartridge 42 to form anaxle around which release liner and transponders are wound andsubsequently unwound.

In certain preferred embodiments source reel or roll 43 is constructedusing materials such as non-petroleum-based plastics, laminated paperlayers, and materials primarily comprised of natural fibers. In anotherpreferred embodiment the entire pre-packaged self-contained supply ofunused transponders is transported to mobile encoder 175, loaded intoit, consumed, and disposed of preferably without generating landfillwaste.

A key aspect of this invention is a complete pre-packaged,pre-assembled, pre-threaded, self-contained supply of encodabletransponders, preferably unlocked with cryptographic access methods. Thesupply is preferably configured for efficient transportation andshipping, conveyance to a work site, and easy loading into mobileencoder 175, preferably in a single fluid motion.

FIG. 21 is a preferred embodiment of system 170 wherein printed symbolsare optically scanned by internal optical reader 226. The embodimentshown in FIG. 21 uses a preferred method of sensing the linear motion ofmobile encoder 220 across a target surface by using an optical mousesensor 225. Such devices are commonly used to track the hand movementsof the operator of a computer. Motion in either the X or Y direction istranslated into numerical displacement representations which when timedare converted into linear velocities. Tracking and processing theprimary axis of motion parallel to the major axis of the release liner,the web speed is preferably controlled by processing means 1756 andtransponder transport means 175C such that transponder 223A advances ata rate of speed that matches the velocity of the entire mobile encoderacross the target surface. Optical mouse 225 tracks displacement acrossthe target surface and also acts as a tamp head to strengthen theadhesive bond of each freshly applied tag. The process of attachment ofthe encoded transponder to the target surface is along a vector that isnearly parallel to the target surface at a speed that is based on realtime feedback from the surrounding environment as sensed by the opticalmouse or other sensor. Optical mouse sensor 225 preferably illuminatesits target surface with either a LED (Light Emitting Diode) or a laser.Avago Technologies of San Jose, Calif. manufactures a variety of mousesensors, both LED-based and laser-based. Laser illumination providessmooth and accurate motion sensing across a variety of surfaces. Themodel ADNS-6150 small form factor lens working in conjunction with theADNS-6530 integrated chip-onboard laser sensor and single-modevertical-cavity surface emitting laser can be used to not only detectmotion in the X and Y directions, but also to some degree in the Zdirection. Displacement along the Z (depth) vector is reported by thedecrease in the number of resolvable features within the field of viewas the target surface fades away from the optical focal point. Thatmeasurement is reported in the surface quality (SQUAL) register.

Optical mouse sensor 224B is used to measure the linear velocity oftransponders as they move along the path of the release liner towardpeel device 222B, as well as sense the gaps and edges betweentransponders 223A and those adjacent to them. The physical outline 178of transponders 223A are a reliable indication of the location of RFIDinlay 181C located within each transponder 223A and enhance systemperformance with reliable positioning relative to near field coupler224A2. The angular velocity of motor 227B and gear train 227A arecontrolled to achieve a linear transponder velocity that matches thevelocity of the mobile encoder itself as it moves across the targetsurface. Therefore an operator with a fast hand motion is just assuccessful as a person with a slower hand motion, both will result in atransponder that lays flat, co-planar with the target surface, void ofkinks or wrinkles that are characteristic of a poorly controlledtransponder application process. In either case, transponder dispensingby transponder transport means 175C will not initiate until opticalmouse sensor 225 preferably illuminates the target surface and detects aminimum number of valid features as reported by the SQUAL registerinternal to the ADNS-6530.

RFID Interrogator 224A encodes RF transponders using either LF (LowFrequency), HF (High Frequency), UHF (Ultra High Frequency), ormicrowave radio energy. Transponders may be powered by radio energy,light, or stored energy from a source such as a battery. RF coupling ispreferably through a near field coupler, an inductive loop or othersuitable transducer 224A2 connected to interrogator 224A to focus RFenergy on a small area within mobile encoder 175, 30, or 220.

Certain preferred mobile encoder embodiments will not encode RFtransponders that fail authenticity tests. In a like manner, RFtransponders will preferably not allow themselves to be programmedunless the interrogator can successfully unlock its secured memorybanks. This is a preferred method of protecting transponder cartridgeand mobile encoder supply chains from counterfeits and knock-offs.Mobile encoder 175 and the transponders loaded into it will only besuccessful in exchanging certain data if certain data encryption andchallenge response protocols are adhered to. In a preferred embodimenteach authorized RFID transponder converter company uses one or moreencryption keys to generate passwords that lock the RF tags, wherebypreventing them from being programmed unless they are unlocked using thesame password. Passwords of this type are specified in the EPC Gen 2specification and in ISO standards. The passwords are preferablygenerated by processing means 175B using a public key from publiclyreadable data such as an asset number or a transponder serial number. Ashared private key is then used by an encryption algorithm such as AESin order to create a password or a collection of passwords that can beused to lock or unlock one or several RF tags. Other methods may be usedthat provide a high degree of certainty that the both the transpondersand the mobile encoders are from legitimate sources. Individual failuresor patterns of authentication failures are preferably reported to acentral database through wireless communications means 175A forsubsequent fraud investigation.

Peel device 222B is part of the mobile encoder and preferably rotates orpivots about pivot point 222A into position 222C and a correspondingposition (not shown) in FIG. 21. Peg 221K helps guide the web to peeldevice 222B. When cartridge 221 is inserted into applicator body 227Fthe web is held in a non-interfering position by guide post 221F and itsaccompanying cartridge guide post such that peel device 222C canself-thread around the transport web without human effort. This is animprovement over prior art where a peel device is an integral part ofthe pre-packaged self-contained supply of transponders and requiresthreading during the cartridge manufacturing process.

Peel device 222B preferably contains a shield on the outer face of theblade, through which radio energy will not pass to encode or interactwith a rejected transponder 223B. The dielectric material of the peeldevice 222B provides sufficient separation from a transponder within theencoding zone and the shield on the back side of the peel device. Thisis another advantage over a peel device that is part of the cartridge,where the cost sensitivity is much more acute. The shielding on the backside of peel device 222B may be any suitable metal attached or adheredin any reliable or economical manner against the non-conductivedielectric structure of the peel device.

Rejecting transponder 223B requires that mobile encoder transponder peeldevice 222B have sufficient clearance from target surface 228 asdetermined by optical mouse sensor 225 using either the SQUAL reading orthe shutter readings. Such readings are used to determine if there issufficient space to advance and rotate a bad transponder 223B around thedistal end of peel device 222B.

FIG. 1 shows a system 10 according to one embodiment of the presentinvention including a mobile encoder 30. And, FIG. 5 details onepossible mobile encoder 30. In this embodiment, the encoder can attachto the belt of an operator, accordingly, mounted on the housing 32 is abelt mounting means such as belt-clip 34, which easily adjusts forleft-handed or right-handed operation and corresponding mounting on thebelt (not shown) of the operator. An external antenna 36 enhanceswireless connectivity to a host or network computer (not shown in thisview), or to a remote-mounted computer device such as a PDA or bar codereader. Several operator indicator lights 227E including a system-readyLED 37, data-ready LED 38, and tag-ready LED 39 mounted on the housingenabling the operator an easy view of the device status.

Also included on the exterior of the housing are an external, power-cordreceptacle 41 so that the on-board lithium-ion, nickel metal hydride, orother appropriate battery 227D may be charged as required. A combinationon/off-next switch 33 enables the operator to selectively power up theencoder. A reset port, such as a recessed reset button (not shown inthis view), enables an operator to reset the software settings of thedevice circuitry on control board 227C as may be required.

A cartridge 42 containing a plurality of RFID transponders releasablymounts to a face of the housing 32. The cartridge further includes atake-up reel 44 for non-dispensed RFID transponders, a port 46 (abovetake-up reel 44 but not shown in FIG. 5) for dispensing commissionedtransponders, and a supply reel 43 for holding blank RFID transpondersprior to commissioning.

In further embodiments, a cartridge 221 containing a plurality of RFIDtransponders releasably mounts to the body of housing 227F. Thecartridge further includes a take-up reel 221J for collecting releaseliner and non-dispensed RFID transponders, and a port through whichblank or securely encodable transponders emerge from source reel 221E.The source reel is comprised of core 221A which may be made from plasticor a recyclable kraft paper fiber to form a wound tube. A tube extendsfrom the walls of cartridge 221 to form axle 221B around which core 221Arotates. Brake shoes 221C create drag, resulting in back torque on thesource core, the magnitude of which is controlled by screw 221D whichwith a knob (not shown) is used to adjust the force applied by brakeshoes 221C. The back torque for cartridge 221 is alternatively developedthrough a motor or an expandable friction coupling into a brakemechanism attached to encoder body 227F.

Take-up core 221H is driven by a tight coupling with drive hub 221G.This tight coupling is achieved through a combination or selection oftight fit, expandable coupling, and sharp teeth. The result is a hubthat will easily slide in or out of core 221H with little effort, butstill be capable of delivering a substantial amount of drive torquethrough that connection without slippage. Drive torque is delivered fromgear motor 227B to hub 221G through drive gear 227A the teeth of whichengage with each other as cartridge 221 is set into position and lockedinto place.

In a preferred embodiment, mobile encoder 30 cryptographically unlocks,encodes, and verifies each transponder one by one. In preferredembodiments, transponders are verified more than once. One timeimmediately after programming with a desired data payload, and thenagain a second time after encoder 220 automatically dispenses an RFIDtransponder 223A onto target surface 228. This second verification stepinsures that the properties of target surface 228 or other nearbymaterials do not adversely affect the performance of transponder 223A.

In another preferred embodiment, encoder 220 is used to encode anddispense a pattern of several transponders 223A onto a target surface228 at regular intervals in order to map the surface of a container forexample in order to determine an optimal location for a placement oftransponders. This information is then preferably used for engineeringand planning purposes for high-volume transponder application in aproduction or distribution facility. Transponders may be designed foroperation in any or all of the UHF, HF, LF, or microwave frequencybands.

In one alternative embodiment, the mobile encoder 64 includes a handle(as FIG. 9 shows, for example) for hand operation of the encoder. Inanother contemplated embodiment, the mobile encoder is fixed to anassembly line in a stationary manner. Accordingly, thestationary-mounted encoder further includes machine-controlled devicesfor extracting a commissioned RFID transponder from the encoder andplaces the transponder on the container of interest by means wellunderstood in the art.

In the aforementioned embodiments of the mobile encoder 30 (or hand-heldencoder 64 of FIG. 8 or FIG. 9, for example) key features commonlyshared include means for enable Gent EPC or ISO standards compliance andmultiple printer-emulation modes. On-board power source 60, such as arechargeable lithium-ion, Nickel Metal Hydride, or other battery enablesfreedom of movement as does means for wireless connectivity to a datanetwork, such as the 802.11 wireless LAN (Wi-Fi), Bluetooth, or otherstandards-based communications protocol. However, a conventional powersource that requires connectivity to a power-grid and a cable-based datanetwork connectivity link would work under certain circumstances.

Further, in contemplated embodiments, the fixed or mobile encoderenables selective mounting to a magazine or cartridge filled withun-commissioned RFID transponders, which facilitates rapid and easyloading of the encoder with ready-to-use RFID transponders and furtherenables re-use, re-commissioning, and recycling of un-dispensedtransponders and the associated cartridge. The mobile encoder can bemonitored and controlled by virtually any handheld or mobile device, ahost computer in a central location, or over the Internet.

Certain features and methods described and explained with relation tohandheld applicators are also relevant to non-mobile RFID tagapplicators that use a magazine, cartridge, reel, or roll to handle,transport, and dispense RFID tags, inlays, transponders, or wirelesssensors. Magazines, cartridges, reels, and rolls are preferably capableof carrying either new or used tags and are preferably capable of beingused in either mobile or non-mobile applicators. Magazines, cartridges,and reels are preferably refilled and reused. Magazines and cartridgespreferably protect RFID tags from ESD.

Cartridges preferably indicate their empty/full status with a visibleindicator such as: an LED, an LCD, a mechanical flag, a window with aview into the source reel, or other such indicators that help anoperator choose which cartridge from which to next consume tags.

The mobile encoder 30 is activated (turned on) when an operatorselectively depresses the combination on/off-next switch 33. However,depressing the on/off-next switch for about three seconds or longerresults in a sleep-mode cycle that can be interrupted by re-pressing theon/off-next switch. In sleep mode the operator indicators (LEDS 37, 38,and 39) will turn off. If active, the mobile encoder system-ready LED 37illuminates and connects to the assigned network. Network connectivityresults in the illumination of both the system-ready LED 37 and thedata-ready LED 38.

Mobile encoders 175 and 30 optionally receive commands and data via thewireless link from the remote computer 154 or optical reader 173.Special bar code commands are scanned by optical reader 173, passedthrough wireless communication means 175A, and interpreted by processingmeans 1756 mobile encoder 175 to perform certain pre-programmedfunctions. Commands originating from either computer 154, optical reader173, or internal bar code scanner 226 (also designated in FIG. 1 asinternal optical reader 175F) perform functions in categories thatinclude power management, data management, wireless configuration,security, configuration options, and utilization of internal resources.

The encoder receives commands and data via the wireless link from theremote computer 20 or host network computer 11 (of FIG. 1). The datarepresents information to be encoded on an RFID transponder. Theinformation is stored in the encoder's on-board memory and the tag-readyLED 39 or 175K rapidly blinks green (cycles on/off to pulsate). An RFIDtransponder is moved from within the cartridge 42 to a position on thetop edge of the cartridge for encoding in the encoder and thetransponder is encoded with the appropriate information. The transponderis tested and if it is good—contains the data and encoding wassuccessful—all three indicator LEDs indicate a solid-green color. Theoperator removes the encoded RFID transponder from the encoder andplaces it on the container of interest.

In the event that the encoding process failed, the bad transponder isdetected and retained by the encoder, where it remains on the take upreel 44 inside the cartridge 42. The take up reel also collects therelease liner as the encoder 30 dispenses good transponders (properlyencoded RFID transponders). The take up reel returns to a re-cyclingcenter where components are re-used or recycled as necessitated.Further, the re-cycling center can perform failure analysis on returnedtransponders.

FIG. 7 is a schematic diagram of additional electro-mechanicalcomponents 70 (as generally referred to in FIG. 6) and logic componentsof a possible encoder 30. An RFID Module 63, such as a MP9311 UHF readermodule available from Sirit Technologies, 1321 Valwood Parkway, Suite620, Carrollton, Tex., 75006, USA, communicates with a verticalpolarized YAGI antenna 62 with a downward side lobe to low-power program(commission) RFID transponders to create an RFID transponder, and thesame downward side lobe and verify transponders at low power also canread far-field transponders at a higher, second power. Additionalcomponents include a mechanical paddle trigger 86 for operator-selectedoverride of the reel of RFID transponder stored in the supply or sourcereel 43 in the cartridge 42. A drive motor 76 coupled to a dual outputshaft gearbox drives the source transponder reel 43 via an intermediatetake-up reel gear interface 78 at the cartridge mouth. Another gearassembly along with a spring couple 85 advances and positions the tagfeeder paddle 84 with feedback from paddle position sensor 88. A tagsensor 74 detects the location of the RFID transponder to-becommissioned by the YAGI antenna 62. As the reel of RFID transponderadvances inside the encoder, the lead edge passes the ratchet post 82.If the now-commissioned transponder is read by the antenna 62 as “good”,a ratcheting-back torque spring 83 enables a peel device, such as theshield and tag peel edge 73, to engage, forcing the commissioned tag topeel away from the carrier layer, which continues on to the take up reel44. In the event of a “bad” tag—that is, the antenna 62 reads the RFIDtransponder and determines an error has occurred—the shield 73 does notengage, allowing the defective transponder to remain on the carrierlayer and proceed to the take-up reel. Once the good transponder isremoved from the encoder, the tag sensor 74 detects the condition andenables the encoder to stand-by for the next event. Transponders areread, written, and verified when an operator initiates an action suchpulling a trigger 86, pushing a button, or some other command sequence.

Certain protective enclosures, such as cartridges 42 or magazines, arepart of a family of interchangeable magazines of similar size, shape,and functionality, which are capable of housing and dispensing certaintypes, styles, shapes, and sizes of new or used RFID transponders.Transponder sizes typically range from 4 mm-thick foam-backedtransponders measuring 12 mm wide down to thin transponders that are 15mm wide on 19 mm pitch.

In at least one embodiment, the magazine or cartridge 42 includes aunique and embedded, RFID transponder which enables automaticinterrogation and tracking of cartridge 42. In certain embodiments, tominimize interference, the cartridge-specific and unique RFID tag orRFID transponder operates in a frequency band that is different than thesupply of RFID transponders contained within the protective enclosure.Alternatively, other embodiments selectively interrogate cartridgeidentification transponders that operate in the same band astransponders within the cartridge that are to be applied.

Certain encoders require replenishment of the battery or other internal,on-board power source 60, such as a fuel cell, or other energy storagetechnology. Accordingly, in some embodiments, an encoder 30 (or encoder64 or encoder 210 of FIGS. 8, 9, and 10) further includes a remote,selectively coupling base unit. The base unit enables a replenishment ofmagazines or cartridges, provides replaceable power sources, rechargesthe on-board power source, serves as a communications gateway, andprovides a user interface for programming and maintenance of theencoder. For example, spare transponder magazines/cartridges areretained in cartridge pockets where they are protected from damage.Cartridges indicate their empty/full status with a visible indicatorsuch as: an LED, an LCD, a mechanical flag, a window with a view intothe source reel, or other such indicators that help an operator choosewhich cartridge from which to next consume transponders. The encoder,also, is retained by a protective pocket to prevent damage and to makeany required electrical or mechanical connections to the base unit. Insome embodiments a base unit mounts to diverse operating locationsincluding various models of fork lift trucks. In such applications, thebase unit includes a variety of wired and wireless communicationsoptions to enable omni directional communication with the encoder,cartridges, a host computer, vehicle mount terminal, a fork truckcomputer, or other relevant computing devices. The base unit includes apower system that is suitable for the application, including powerfiltering and energy storage capabilities such as batteries or fuelcells.

As with all ESD-sensitive equipment, care must be taken to avoid abuild-up of damaging electrostatic charges. Accordingly, in certainembodiments charge is removed using a variety of conduction methodsincluding wiping, air, and humidity controls, or use of specialmaterials that contain short conductive elements optionally arrangedwithin a flexible elastic cord.

In some embodiments, the encoder adapts to use a particular type of RFIDtransponder. One type of suitable RFID transponder is model numberAD-220 from Avery Dennison of Brea, Calif. or, alternatively, Raflatacmodel 300846 from Tampere, Finland, or a Spider transponder or FT-33 FATtag from RSI ID Technologies of Chula Vista, Calif. Such a transponderis die cut and adhered to release liner. Additionally, wireless sensorsare manufactured to specifications that are compatible with the specificencoder, including such specifications as core diameter, outer diameter,and web width. Alternatively, certain steps are required to prepare astandard roll of ALL-9338-02 tags for use in an automated encoder,including unrolling from a large roll (up to about 6-inches in corediameter) onto several smaller rolls having a smaller core diameter (ofabout 1-inch to about 2-inches in core diameter).

Encoder 30 communicates with a remote computer and includes options tophysically, electrically, and communicatively integrate with a portabledata terminal (PDT) or a mobile computing platform. Certain PDT's have avariety of wireless connections including PAN and WLAN. Certain PDT'sinclude a bar code scanner comprising a laser, an imager, or othermeans. In other suitable PDT's an RFID interrogator and antenna arebuilt-in, while certain others have a card slot manufactured to astandard such as PCMCIA, CompactFlash, or Secure Digital, into whichinterrogator/antenna is plugged into. An example of such a card is theMPR 5000 that plugs into a PCMCIA Type II slot and is available from WJCommunications of San Jose, Calif. The MPR 5000 is compatible withhandheld computers such as the Hewlett Packard iPAQ5550 or other modelsthat accommodate smaller card-form factors, enabling them to read andwrite EPCglobal or ISO 18000 compatible UHF RFID transponders.

Other events, information, and status—such as changes in transponderreadiness, transponders remaining on the source roll, remaining chargein the battery, changes in range-status between certain predefinedstates such as Close, Near, and Far—are communicated to the associatedPDT. Other possible information, including certain power managementfunctions, commands, status, and data-to-be-encoded into each readiedtransponder, is provided to the PDT over a wireless connection. Such aconfiguration puts the encoder in the role of a peripheral device to thePDT 219, with PDT 219 managing the primary user interface and mostcomputation functions.

In some embodiments the encoder adapts to exchange information with ahost device, including a PDT, in either a batch-mode or through a realtime connection. Batch mode uses a periodically connected data transferchannel such as a wired connection. Certain wired connections includeserial data, infrared, optical, Universal Serial Bus, a parallel port,or other physical data connection. Certain real-time connections includewireless data links including Personal Area Network (PAN), WirelessLocal Area Network (WLAN), and Wide Area Network (WAN). Certain PANconnections include Bluetooth and Zigbee. Certain suitable WLANconnections include IEEE 802.11a, IEEE 802.11b, and IEEE 802.11g.

For certain encoder embodiments passwords are encoded into transpondersor wireless sensors when they are commissioned. Passwords aresafeguarded using cloaking, obfuscation, cryptographic techniques,secure and trusted channels, locked memory, and other methods that arecommonly used to protect confidential information. Passwords aregenerated or retrieved from data encoded in an RFID transponder togenerate an index into one or more databases that contain a onedimensional array of passwords, a two dimensional array of passwords, amultidimensional array of passwords, or an array of actual or pointersto algorithms used to generate passwords from transponder data, forexample. Alternatively, cryptographic algorithms are used to generatepasswords from transponder data.

Although this disclosure makes specific reference to a mobile encoder,it is understood that the encoder can easily adapt and be readilyconfigured to a fixed operating environment. For example, it can bemounted to a forklift truck or a high-speed conveyer line and maintainadvantages of wireless communication, rapid change-over and otherqualities as discussed and developed more fully in this disclosure.

Interrogator Apparatus

Working as a stand-alone device, or combined with an encoder, certainembodiments of the present invention include an RFID transponder reader,also called an interrogator. The interrogator, in one embodiment, is aphysically separate device that is solely in wireless communication withthe encoder. In another embodiment the interrogator includes a wiredconnection to the encoder. In yet another embodiment, the interrogatorconnects to the encoder via an intermediate processor, such as a remotecomputer, or some other intermediate device. In yet another embodiment,the intermediate device is a shared processor in a physically integratedencoder/interrogator apparatus.

Regardless of the physical configuration of the interrogator, itsfunction is to encode and/or verify a RFID transponder's (includingwireless sensors) functionality. Certain embodiments use a mobilehandheld reader to verify transponder functionality after cartonattachment. Certain handheld readers also read bar codes that eitherpartially or completely specify the data that is to be programmed into atransponder. Accordingly, an optical path from the interrogator to alocation for reading bar code labels is used to identify certaininformation about the objects or containers that are to be tagged.Additional transponder encoding instructions and data is acquiredthrough an integral network interface or a batch mode memory in theinterrogator.

In certain embodiments, a shield structure incorporated in a combinedinterrogator/encoder prevents RF fields from interrogating orreprogramming RFID transponders yet-to-be-commissioned that are residentin the combined interrogator/encoder device.

In one embodiment, shown as a cross-sectional schematic in FIG. 8, acontact image sensor (CIS) 90 or a linear optical array is used to scanalong the length of an RFID transponder before it is applied to acontainer. CIS 90 produces a video stream that is decoded and theninterpreted and stored by an on-board Computer 61. CIS or a similarlinear array sensor is capable of reading both linear andtwo-dimensional bar codes. In certain embodiments, CIS readstwo-dimensional bar codes before attachment to inlay or transponder. Theon-board computer creates a logical association between bar codes andthe commissioned RFID transponder. Encoder 64 reads and associates allbar code symbols on a single segment with the RFID transponder or inlayadhered to it.

In FIG. 10 when an operator pulls the trigger 86, which is either amechanical trigger or an electro-mechanical device, the on-demandcommissioning of the RFID transponder occurs and nearly simultaneouslyis pressed against a container within a fraction of a second. In certainembodiments, mechanisms internal to encoder 64 transfer mechanical forceto the RFID transponder tag through the use of air, springs, motors,plungers, elastomers, or other energy storing or delivering methods.Reloading of the next tag (next transponder) and readying of the systemare performed within a time interval that is acceptable to the operatorand enables a high degree of productivity for tagging cartons, pallets,or other transport containers.

In certain embodiments of a combined interrogator/application, a trigger86 couples to an electrical switch having one or more stable positionsthat are detectable by a controller. In certain modes of operationtrigger-switch state is coupled with range information from a sensorsuite 218 to execute functions at predetermined ranges at predeterminedtimes. The result is a trigger that functions based upon detected rangefrom a container or other object of interest. This advantageouslyimproves operator efficiency and productivity as one trigger executesseveral different functions that are typically involved with RFIDtagging including the tagging of bar-coded cartons that have beenselected to receive wireless sensors.

Verification of bar code occurs either before or after an RFIDtransponder is commissioned and the tag applied to the container bymerely stepping back to a point where the sweep angle of a laser beam orfield of view of an imager can read a bar code label. In certainembodiments ranges shorter than that, but not in Close Proximity, areused for sweeping a radio frequency interrogation signal across thefaces of multiple cartons to assure that the correct tags, the correctnumber of transponders, and the correct data within that transponderswere all properly programmed.

In certain embodiments Close Proximity range is reserved exclusively forprogramming, applying, and verifying one transponder, all in a singlepull of trigger. In other embodiments, the interrogator includesprogrammable conditions that enable Trigger Events to interact withexternal devices or nearby equipment. For example, at a predeterminedrange from the interrogator, activation of the trigger causes theencoder to transmit a coded signal to an external device as anindication of an operator action: at a Far-range the signal to requestsan external device to read a bar code and the bar code information isdecoded and transmitted back to encoder. In another embodiment, decodedbarcode information is processed by a portable data terminal (PDT), avehicle mount terminal, or other computing device.

The on-board computer 61 controls the operation of the RFID InterrogatorModule 63 to read, write, and verify RFID tags, inlays, transponders,and wireless sensors that are applied or are within range of theinterrogation fields produced by antenna 62. The encoder 30, capable ofreading multiple RFID transponders near it, can, in certain embodiments,produce a linearly polarized radio field via the internal antenna 62. Inanother embodiment, the internal antenna produces a horizontallypolarized RF field. A commissioned transponder can be read both beforeand after it is applied to a transport container. When multipletransponders are within the interrogation field of the encoder 30 withan interrogator module 63 the on-board computer 61 determines whichtransponders are commissioned and dispensed versus those transponderthat have not. In certain embodiments, the on-board computer maintainsrecords of transponders recently applied in order to properly determinehow to interact with each transponder in the field of the internalantenna or other antennae under the control of RFID Interrogator.

In one possible embodiment, the interrogator/encoder utilizes preprintedinformation on a set of RFID transponders. The pre-printed informationincludes one or more logos, an EPC-global Seal, and other informativealpha-numeric or bar-code data. Certain preferred embodiments ofencoder/applicators 30, 64, and 210 correlate RFID tag data with dataencoded in certain preferred bar codes. In certain preferredembodiments, applicators such as applicator 30 read the bar codepreferably using a sensor such as CIS 90 as the tape is unrolled from aspool. In certain other preferred embodiments, an RFID tag is located oncartridge 42 and contains a numerical value that is directly orindirectly representative of the numerical values optically encoded intothe bar codes preferably at least indicating the starting numericalvalues of a number sequence. Other additional information is alsoencoded in the RFID tag in certain preferred embodiments, including thenumber of tag positions, the number of good tags, the ending sequencenumber, the date, time and place of tag conversion or other preferredcommercial, logistic, or manufacturing information. In certain preferredembodiments of applicators 30, or 210 certain wireless tags attached tocartridge 42 are capable of being read. In certain preferred embodimentsthe interrogator such as interrogator 63 is capable of reading an RFIDtag mounted to the loaded cartridge, and is also preferably capable offiltering out its response to interrogation or programming of RFID tags.

Certain embodiments have a motorized tape drive and dispensing system.Certain embodiments contain some or all of the following: a rechargeablebattery, an operator display, a wireless interface, a network stack, anIP address, a PCMCIA port, a Compact Flash port, a USB cable, a serialcable, a dock port, a window to allow the operator to view thetransponder attachment process, or a bar code scanner.

One suitable interrogator includes model MP9311 available from SiritTechnologies of 1321 Valwood Parkway, Suite 620 Carrollton, Tex. 75006,USA. Other RFID transponder or wireless sensor interrogator modules withother feature sets are also possible for use in theinterrogator/encoder.

FIGS. 8 and 9 show one possible interrogator/encoder 64 according to thepresent invention. The interrogator/encoder 64 comprises a housing 65having a user input device 67, such as a key pad or key board, and auser output device, such as an LCD screen 68, for displaying opticallyscanned label data, RF interrogated data from a transponder, and otherinformation including on-board diagnostic functions, bios status, andexternal information provided from a remote computer as sent over awireless network, for example. A handle structure 66 enablespoint-of-use deployment while cartridge 42 enables on-demandcommissioning of RFID transponders, which are dispensed from thetransponder port 46. In this embodiment, an integrated YAGI antenna 62creates a large forward-looking main lobe of radio frequency energy forinterrogation of commissioned RFID transponders. The internal antennaalso produces side lobes of RF energy that although attenuated from themain lobe by several dB, couple enough power into nearby readiedtransponder to interrogate and write to it.

As further depicted in FIG. 10, a reflector 219 b passively reflects RFsignals from an upper side lobe downward toward readied tag 216 f.Backscatter from tag 216 f propagates to both antenna 219 a andreflector 219 b for processing by the interrogator. Having such anantenna embedded in PDT 219 and mounted to the structure of the encoderhousing enables the PDT 219 to encode and verify readied transponder 216f while commanding the encoder to commission and dispense a tag when aparticular Trigger Event or a predetermined range status change occurs.

An antenna, or alternatively, leaky coax 212 a or a near-field coupleris located outside of protective enclosure of cartridge 42 in a locationvery close to the tag attachment zone in front of a tamp head or tagapplication roller and holding rollers 216 d or hammer 216 a.

In some embodiments antenna 212 b is a patch antenna with a radiationpattern toward the tag attachment zone. In other embodiments the antennais a near field coupler. Alternatively, leaky coax, a type of coaxialcable having slits, slots, or perforations that allow radio frequenciesto leak in or out, is used in encoders according to the presentinvention. A coupled-mode cable, which does not radiate as well asradiating-mode cable, is constructed with closely spaced slots in acorrugated outer conductor. Radiating-mode cable typically has a foilouter conductor with non-uniformly spaced slots arranged in a periodicpattern. Coupled-mode cable is a slow-wave structure. In free space itsexternal fields are closely bound to the cable and do not radiate,except for minor end effects according to “Prediction of Indoor WirelessCoverage by Leaky Coaxial Cable Using Ray Tracing” by Samuel P. Morganof Bell Laboratories, Lucent Technologies.

In certain embodiments an interrogator drives a signal into a leaky coaxthat is terminated in a purely resistive load of about 50 ohms. AnRF-switch selects between radiating and non-radiating loads including anantenna or leaky coax and, therefore, avoids mismatched load impedance.

In other embodiments internal antenna 212 b or 212 c is a patch antennawith its strongest lobes oriented toward the tag holding and placementarea in the region of holding rollers 216 d. Antenna 212 c or leaky coax212 a work with an interrogator to produce electromagnetic fields tointerrogate, program, and verify wireless sensors. Shield 217 e preventsinterrogation or programming of RFID transponders until they arrive atseparation roller or tag peel edge 217 d. A reflector is used in certainembodiments to reflect RF radiation toward a readied transponder. In theevent that verification fails, the operator is informed that the bad tag(or inoperable transponder) is to be discharged onto a surface of athird object other than the encoder or the transport container, forpost-mortem analysis.

Referring to FIG. 10 drive motor 76 is preferably located inside thecenter of source reel 43 within the circular walls of applicator housing211 b, around which cartridge 42 is nested when mated tointerrogator/encoder/applicator 210.

Motor 76 is mounted to the structural frame of applicator 210 andpreferably transfers mechanical power to certain drive points preferablyusing gears, belts, or drive shafts within applicator housing 201 a or211 a. In certain preferred embodiments of applicator 210 certainpreferred drive points include take-up reel 44, source reel 43, orhammer arm 216 a.

Trigger 86, preferably embedded within trigger handle 66 is actuated byan operator, preferably causing a Trigger Event. In certain preferredembodiments, there is more than one kind of Trigger Event. In certainpreferred embodiments of applicator 210 certain types of eithermechanical or electromechanical actuators are preferably used to causehammer mechanism 216 a to trip, being driven toward readied tag 216 f,through port 46 for placement on a transport container at the face ofbulkhead 211 a.

Another means of electromechanical actuation from a Trigger Eventinitiated by sensor suite 218 is illustrated in FIG. 10 whereby DC motor215 c runs in a reverse direction causing ratchet 216 b to becomedisengaged, allowing hammer 216 a to accelerate toward tag 216 f due tothe torque exerted by spring 216 c. Hammer 216 a passes between holdingrollers 216 d to press tag 216 f against the face of a transportcontainer.

Interrogator 212 d is preferably capable of working with controller 213b to recognize which tags have been recently programmed or applied so asto filter out their response to interrogations of other tags, especiallythose tags that are being prepared for attachment. Interrogator 212 d ispreferably capable of modulating its transmitted radio power to affectthe range and signal to noise ratio of its coupling to wireless tags.

Method of Using Smartphone for Encoding

FIG. 11 shows a method for using a smartphone for encoding RFID tags byusing the built-in camera as a barcode scanner. In step 111 a smartphoneis positioned to capture the image of a barcode. The barcode can be 1Dor 2D, it can carry GTIN or other information. It can already have aserial number such as a serialized Data Matrix barcode for apharmaceutical item or container. In step 112 the image is decoded andprocessed by software. In step 113 the payload for a transponder iscomputed, preferably using serialization algorithms that are presentlydescribed. In step 114 a transponder is encoded with the transponderdata payload. The transponder encoding apparatus is either built intothe smartphone or attached to it as a peripheral device.

Referring to FIG. 22, smartphone 154 is shown as an Apple iPhone with aperipheral encoding device attached to the accessory port. A peripheraldevice such as this is one embodiment, in other embodiments thecomponents described herein are contained with the enclosure ofsmartphone 154. Near field couplers 238 a and 238 b are used to couplemagnetic fields with a nearby transponder for RFID transponder andwireless sensor authentication. Certain preferred embodiments use onecoupler to transmit and the other to receive. Such embodiments thereforerequire close proximity of both couplers to a transponder in order toread or write transponder data, or to verify transponder authenticity.FIPS 140-2 module 239 has a cryptographic boundary that is preferablycompliant with U.S. Government Federal Information Processing Standard140-2 which is incorporated by reference herein. Module 239 detectstemperature variations that are outside of upper and lower temperaturelimits which is one possible mode of cryptographic attack. It also hastamper detection that detect a physical breach of a mesh or otherdetection barrier. FIPS140-2 compliant cryptographic module 239 is usedto hold cryptographic keys and to perform cryptographic functions. Ifthe module detects an attack, the memory for storing cryptographic keysis immediately cleared. Module 239 preferably uses non-imprinting memoryand therefore leaves no trace of the cryptographic information afterbeing cleared.

Method of Tagging Containers

FIG. 12 is a block diagram representing a second method according to thepresent invention including applying RFID transponders to objects ofinterest. One suitable object of interest comprises transport containerssuch as corrugated cartons or shrink-wrapped cases on a shipping pallet,which is inadequately addressed by the prior-art, particularly forsolutions for manually operated automatic encoding and attachment to acontainer.

Block 121 represents a process step including the identification andselection of a container to be tagged with an RFID transponder orwireless sensor. In one embodiment this step includes a manual selectionand verification processes that consists of manual handling, visualsighting, and scanning bar codes with a hand-held optical reader device.This method contemplates that a transponder encoding scheme is ready inadvance and synchronized with a pick list, customer purchase order,advanced shipping notice, and other such records to assure that goodsare properly moved and accounted for. Preferred bar code scannersinclude those that allow an operator to freely handle cartons with twohands. Such scanners include laser bar code scanners or imagers that areworn on either that back of the operator's hand or near the top knuckleof a finger. Such scanners are described above, and preferably have aBluetooth or similar wireless interface to connect to mobile encoder 175or 30. Bar code scanner 226 of FIG. 21 is a preferred embodiment of analternative device that combines manual bar code scanning and RFIDtransponder encoding into a single handheld device. The operator maychoose to scan bar codes that contain data, application identifiers,commands, or other elements commonly found in automatic data captureapplications.

Block 122 represents the process step of processing bar code informationto derive the underlying data. Depending on the type of bar code, how itis encoded, and its purpose, different processing steps will be used. Inpreferred embodiments the bar code may contain SKU information, a GTIN,an SGTIN, EPC data structures, a military UID, an SSSC, an asset number,a file identifier, or other such identifying information. In certainpreferred embodiments, the bar code (either one or two dimensional)contains a partial or complete description of the data that is to beencoded into the RF transponder. Such bar codes are described in ISO/IECdraft document PDTR 24729-1. Application identifiers 01 and 21 arecombined with additional encoded printed information to fully specify aserialized GTIN (or SGTIN). Using such bar codes does not require theuse of additional data in order to generate RF transponder payload data.Mobile encoder 175 may therefore independently receive and process theRF transponder payload information. One type of bar code is used tosignal mobile encoder 175, 30, or 220 that it should enter a modewhereby it performs a serialization algorithm without using an AI 21 barcode. This process step of identifying the information to be encoded maybe included in the step represented by Block 121. In this step (Block122), an operator may use a bar code reader or an encoder/interrogatorof this disclosure. Alternatively, the operator may receive instructionsdelivered to a hand-held PDT or other mobile data terminal connected toa wireless network. This information is delivered to an encoder, such asencoder 30.

Block 123 represents another process step whereby, using a mobileencoder, the operator then commissions an RFID transponder with theinformation of the previous step (Block 122). Optionally, successfulcommissioning of the RFID transponder is verified by the encoder. In oneembodiment, the encoder tests the next transponder and determines if itis operating within certain predefined specifications includingparameters such as activation energy, backscatter signal strength,sensor performance, and other indications of the quality of thetransponder. If the encoder determines that the transponder is notlikely to result in a successful transponder deployment as may bedetermined by failure on multiple encoding and verification attempts ordue to either physical or electronic deficiencies or abnormalities, thenthe operator is informed and the failed or bad transponder is discardedautomatically or when an operator pulls a trigger under anoperator-acknowledged transponder failure condition.

This step (Block 123) also includes processes to read or determine bydead reckoning the information encoded into certain preprinted opticallyencoded symbols on the outward facing non-adhesive surface of theadhesive tape. In certain embodiments the adhesive tape is printed withinformation. In other embodiments the printed information is amachine-readable symbol such as a bar-code symbol. For example, one ormore machine-readable symbols are read when the tape is prepared for usein an automated encoder or, alternatively, during the inlay conversionprocess and conveyed to an encoder through other data storage means,such as an RFID transponder. In one embodiment, an information encodingmethod uses either one-dimensional or two-dimensional bar codes. In someembodiments a linear imager is used to read either linear ortwo-dimensional bar codes as the tape is being unrolled from a spool.Some encoding schemes preprint machine-readable symbols at regularintervals along the length of a roll of adhesive tape. In certainembodiments the spacing of the preprinted symbols is at an interval ofone half of the nominal length of each section of adhesive tape. Incertain embodiments, the encoded information is used as a reference toone or more data storage locations. In other embodiments the datastorage locations are accessible through a computer network. In someembodiments, the encoded information is a series of sequential numbers.Information relating to data stored in the RFID transponder is stored indata storage locations that are referenced by one or more of thepreprinted symbols. In an alternative embodiment more than one type ofmachine-readable symbols can be read from the surface of a segment oftape. In certain embodiments, more than one machine-readable symbol isused as a reference to the same or closely related data records ofinformation stored in the RFID transponder or inlay, and either can besuccessfully used to access stored data.

In some encoders used in this step (Block 123) a Trigger Event occurs,which results in the verification that a particular commissioned RFIDtransponder has been tagged and associated with a specific container.This Trigger Event occurs, in certain embodiments, when an operatorpulls a trigger on the encoder. In other embodiments the Trigger Eventoccurs when certain sensors detect preprogrammed conditions relating tothe proximity of the encoder face to an object that is to be tagged.

Finally, (Block 124) the operator applies the RFID transponder on thecontainer and, thus, commissions the transponder. In certainembodiments, the location of the targeted placement of the RFIDtransponder or wireless sensor on the container is stored in a database,which is referenced or pointed to by information that is stored in thememory of the encoder. In one embodiment, the operator holds the encoderagainst the face of the container based on the tagging requirements forthat particular container. The tagging requirements including thelocation and orientation of the RFID transponder to be placed isconveyed visually or aurally. For example, the operator receives visualinformation via a screen or display on the encoder. In certainembodiments, physical indicators are attached to the encoder and extendfrom its body in a direction and manner so as to assist the operator inthe positioning of the transponder onto the carton. In otherembodiments, transponders are applied to the interior of a carton,before it is sealed.

Method of Commissioning RFID Transponders Using a Mobile Applicator.

FIG. 13 is a block diagram showing a method according to the presentinvention for commissioning RFID transponders using an encoder, such asthe encoder 30, couples to a cartridge or protective enclosurecontaining a plurality of RFID transporters releaseably mounted on atransport sheet or roll. The encoder enables the roll of RFIDtransponders to advance one position (Block 131), placing the Next Tagin a test 1 position. The Next Tag is tested (Block 133) to ensure thatit performs within predetermined parameters such as activation energy,backscatter signal strength, sensor performance, and other indicationsof the quality of the transponder. One possible method includes encodinga transponder using only a minimal amount of radio-frequency energy.Since transponder encoding requires more energy than reading atransponder, this low power test constitutes a basic test of bothminimal activation energy and backscatter signal strength.

An RFID transponder that fails this test (Block 133) results in a “BadTag” status and proceeds to the take-up reel of the encoder (Block 135).Thus, any failed transponder remains captive in the cartridge and cannotbe released from the encoder by an operator. Optionally, the operator isnotified of the failed transponder so the operator can request a newlyencoded transponder (Block 137). However, in one embodiment, thenotification step occurs automatically, and a newly encoded nexttransponder is generated without input from the operator.

Block 132 shows that a “good” transponder is positioned in the encoderfor the encoding process. The RFID transponder that passes the test 1position is commissioned with predetermined data based on the containerto be tagged. Methods of obtaining, storing, encoding, and commissioningthis information on the RFID transponder are discussed elsewhere in thisdisclosure.

The commissioned transponder undergoes a verification process (Block134) to determine if the intended information was successfully encodedon the RFID transponder. Certain embodiments combine the verificationstep with the encoding step to gain operational efficiencies. If thisverification test results in a fail condition, the transponder remainsin the encoder and ultimately winds on the take-up reel in the cartridgefor subsequent post-mortem failure analysis.

Block 136 represents a pass condition. The encoder removes thecommissioned RFID transponder from the transport web or release liner,enabling the operator to retrieve the transponder from the encoder andin Block 138 apply the transponder to the container. In an alternativeembodiment for Block 138, the operator or a fixture holds the encoderagainst a surface of the container and the encoder places thecommissioned RFID transponder directly on the container without operatorintervention.

FIG. 14 is a system diagram that illustrates a preferred serial numberallocation system according to the present invention. Blocks of serialnumbers are allocated to RFID printers and encoding devices such as RFIDencoder 155 of FIG. 15 as described in more detail below. Each objectclass, represented in FIG. 14 as GTIN's, has its own separate serialnumbering space. As described above, the entire object class serialnumber space is subdivided into sectors that are defined by a limitednumber of most significant bits of the serial number field. In the caseof a GS1 SGTIN-96 key type, the serial number field is 38 bits long.

To show how this is accomplished in Serial Number Database 140, arepresentative object class is managed by Table GTIN A 141 and is shownto have three serial number block sizes of lengths 10, 11, and 12 bits.Within table 141 are three rows, or tuples 141 a-c. Each row or tuplecontains two columns or attributes: a starting serial number and theamount of remaining space until the next serial number block. Inpreferred embodiments, the remaining space is expressed in units ofblocks of the selected block size.

Now by way of a more detailed example, allocation of blocks of serialnumbers of different sizes is shown as requests are encountered over aperiod of time. An initial request is made for serial number Block 0 144for GTIN A that is 10-bits long. At that time then all of the rows oftable 141 show the same starting number of 000000. When the initialrequest for a 10-bit block is granted for block 144, the starting numberfor the next block of that size is increased to the end of the first10-bit block and the remaining blocks is computed based on the followingalgorithm: the starting point for the 11-bit block 141 b is adjusted tothe next greatest unused number that contains all zeros in the bits thatrepresent the next assignable block of that size. The same is done for12-bit block 141 c and so forth unless those blocks have already beenassigned to an RFID encoder 155 using for example Block 1 145, in whichcase they are not changed. The remaining counts values for each blockwill remain at zero for each block that is not bounded on the upper sideby an assigned block of another size. If a serial number block isbounded, then the remaining count value is adjusted to accuratelydescribe the number of serial number blocks that can be assigned. Ifadditional blocks of that size are subsequently required, then, spacepermitting, a new block starting number is assigned and the processcontinues until the entire serial numbering space is fully allocated.

In preferred embodiments, a request is made by smartphone 154 as shownin FIG. 15. The smartphone preferably performs biometric authenticationas shown in step 161 of FIG. 16. In step 162, using smartphone 154devices such as camera 237 of FIG. 22 a biometric match for a face,iris, voice, or fingerprints breaks the retry loop with an authorizationto continue to step 163. In step 163 transponder encoding is enabled andsmartphone 154 is authorized to request, as a lower database level,blocks of serial numbers for specific object classes, such as certainGTIN's. RFID printers and encoders 155 are preferably then readied forencoding. Biometric security enables brand owners to enforce securityprocedures within their own plants and at contract manufacturinglocations all over the world.

Table GTIN B 142 and Table GTIN C 143 show that each GTIN is managedseparately to provide unique serial number blocks such as Block 2 146,possibly according to different rules. In fact since GTIN's aretypically purchased and owned by brand owners, and database 140 may beused to manage serial number allocation for multiple brand owners, thenthe rules that are applied to the various GTIN object classes in FIG. 14may be different. Retail brand owners may want linear serial numberassignments within each block while a pharmaceutical brand owner maywant to have randomly assigned serial numbers within each serial numberblock. In a preferred embodiment allocated block 141 c is issued to alower database level or directly to an encoder's internal memory forcommissioning transponders with randomly assigned serial numbers fromwithin the range of numbers that are defined by that allocate block 141c.

Brand owner A with GTIN A may also have serial number blocks managedwith a finer granularity than brand owner C with GTIN C. Furthermore apossible reason for brand owner C to select very large block sizes asshown in Table GTIN C 143 is to allow serial number allocation to bemanaged according to a different method such as chip-based serializationfrom chip manufacturers Impinj, Alien, or NXP for example.

FIG. 15, a block diagram, shows the essential parts of a system tomanage unique serial numbers on a global scale using smartphones asmobile remote computers. Server 151 is a computer running a serverapplication such as an Apache HTTP web server on an operating systemsuch as Unix, FreeBSD, Linux, Solaris, Novell NetWare, Mac OS X,Microsoft Windows, OS/2, or TPF. Web server 151 can be owned, borrowed,or rented by the slice from cloud service providers.

SQL database 152 preferably conforms to ISO/IEC 9075 and its variousparts. In other embodiments, a database other than SQL is used toperform the data storage and retrieval functions described herein. SQLqueries are preferably performed with the declarative SELECT statementwhich retrieves data from one or more tables, or expressions.

Script 153 preferably executes on server 151 and is written in ageneral-purpose server-side scripting language such as PHP to producedynamic web pages.

A segment of PHP code that is used to store RFID tag commissioning datais:

$stmt=$this->db->prepare(“INSERT INTO SGTINs(CommissioningReport_EncStatus_SessionNum, SGTIN, GTIN) VALUES (?, ?, ?,?)”);

$stmt->bind_param(“ssii”, $attrSession, $sgtinN, $attrGtin);

$stmt->execute( );

$stmt->close( );

Smartphone 154 preferably uses asynchronous data transfer techniques ina multi-threaded computing environment to communicate with script 153 inserver 151 to prevent thread-blocking that gives the appearance of theprogram seizing up while waiting for a database transaction to becompleted. Certain preferred embodiments use ASIHTTPRequest on Apple iOSsmartphones to request a transaction with a remote database withoutblocking a major program thread. Below is an example of an iOS functionto store an XML commissioning report from RFID encoder 155:

  -(void)SQLStoreRecentTaggingForString:(NSString *)recentTagging { NSURL *url = [NSURLURLWithString:@“http://www.adasainc.com/update.php”]; ASIFormDataRequest *request = [ASI Form Data RequestrequestWithURL:url];  NSString *comTagStrTrimPhp = [recentTaggingstringByReplacingOccurrencesOfString:@“ ” withString:@“”]; NSLog(@“SQLStoreRecentTaggingForString: ‘%@’”,  comTagStrTrimPhp); [request setPostValue:comTagStrTrimPhp forKey:@“comTags”];  [requestsetDelegate:self];  [request startAsynchronous]; }

The method startAsynchronous is used on the request to start a databasetransfer on a separate computing thread. This is one important aspect ofasynchronous data transfer in periodically connected system nodes.Another example is in the collection of XML report data from RFIDencoder 155, piece by piece to assemble a complete string. The iOS codeline [scanner.readRecentString appendString:trimStr]; illustrates howtrimStr is appended onto a string, in this case named readRecentStringthat is an NSMutableString that is allocated as part of an instance thatcoordinates communications with a particular RFID encoder. Once the endtag is received, then iOS program assembles a request to store tagcommissioning data. The iOS program is also ready to receiveauthorizations from server 151 as responses are returned from it. Theauthorizations are preferably able to be stored and retrieved when thesame RFID encoder 155 reconnects with smartphone 154. This system designtherefore illustrates a preferred method for collecting commissioningdata, storing it in an SQL database, and delivering new encodingauthorizations to RFID encoders like RFID encoder 155 without requiringany realtime connections to a remote database.

RFID Transponder 156 receives and stores a globally unique identifiersuch as an SGTIN-96 through an intermittently connected chain ofcomputers and programs as described above and as illustrated in FIG. 15.

In FIG. 23, Block 240 is used to scan a barcode, such as a GTIN. InBlock 241 the RFID transponder payload is computed, preferably usingserialization algorithms and methods that are disclosed herein.

Block 242 represents the process step whereby mobile encoder 175, 30, or220 encodes an RFID transponder with the information of the previousstep (Block 241).

Successful commissioning of the RFID transponder is preferably verifiedby the encoder as shown in Block 243. In one embodiment, the encodertests the immediate transponder and determines if it is operating withincertain predefined specifications including parameters such asactivation energy, backscatter signal strength, sensor performance, andother indications of the quality of the transponder.

If in Block 244 the encoder determines that the transponder is notlikely to result in a successful transponder deployment as may bedetermined by failure on multiple encoding and verification attempts ordue to other evidence of physical or electronic deficiencies orabnormalities, then the operator is optionally informed and the failedor bad transponder is discarded automatically as shown in Block 245.

Block 246 is the process of using motor 227B and/or transpondertransport means 175C to pull release liner 182 tighter and tighter suchthat webbing 182 advances forward to the point that the leading edge oftransponder 178 extends past the distal end of peel device 183 or 222B.

In Block 247 web 182 is pulled forward to the point that transponder 178or 223A begins to rotate around peel device 183 or 222B. It is in thisstep that either a human finger or some target object needs to bepresented in the rotational path of the tipping transponder 178 or 223Amust be located. In the case of mobile encoder 30 where the operator isrequired to handle the encoded tag, it is important that their finger bepresent as transponder 178 begins to tip, allowing adhesive layer 181Dof transponder 178 to make contact and be removed for placement on atarget object such as a shipping container, trackable asset, automobilewindshield, or other object of interest. In cases where the operatorscans a bar code and applies encoded transponder 178 in a single motion,mobile encoder 220 is preferred, wherein as transponder 178 tips as itrotates around peel device 222B adhesive layer 181D sticks directly ontotarget surface 228. In either case, encoded transponder 178 is caughtmid-rotation and adhesive layer 181D provides adhesive forces sufficientto completely detach transponder 178 from release liner 182, thuscompleting the function of Block 247 where work flow returns to Block240 for another transponder encoding cycle to begin.

While the invention has been particularly shown and described withreference to certain embodiments, it will be understood by those skilledin the art that various changes in form and detail may be made withoutdeparting from the spirit and scope of the invention.

I claim:
 1. An RFID transponder comprising: a substrate; an antennastructure formed on the substrate; and an RFID integrated circuit chipwhich is electrically coupled to the antenna structure, wherein the RFIDintegrated circuit chip is encoded with a unique object number, theunique object number comprising an object class information space and aunique serial number space, and wherein the unique serial number spacehas an allocated block stored therein defined by a limited number ofmost significant bits of the unique serial number space as designated byan external numbering authority.
 2. The RFID transponder of claim 1,wherein remaining bits of lesser significance of the unique serialnumber space are encoded with a unique serial number for the objectclass.
 3. The RFID transponder of claim 1, wherein the object classinformation space is encoded with information comprising a companyprefix, an item reference, a partition value, and a filter value.
 4. TheRFID transponder of claim 1, wherein the unique object number is aportion of a serialized global trade item number.
 5. The RFIDtransponder of claim 4, wherein the serialized global trade item numberis an EPC SGTIN-96 encoding.
 6. The RFID transponder of claim 1, whereinthe unique serial number space is at least 38 bits.
 7. The RFIDtransponder of claim 1, wherein the allocated block is defined by atleast 3 most significant bits.
 8. The RFID transponder of claim 1,wherein the allocated block is assigned based at least in part on ablock starting serial number and a block size number within the uniqueserial number space.
 9. The RFID transponder of claim 1, wherein theallocated block is one of a plurality of allocations intermittentlyreceived by an encoder from an external numbering authority.
 10. TheRFID transponder of claim 1, wherein the RFID integrated circuit chip iscomprised of silicon.
 11. The RFID transponder of claim 1, wherein theRFID integrated circuit chip is comprised of polymer.
 12. The RFIDtransponder of claim 1, wherein the substrate, antenna structure, andRFID integrated circuit chip are covered by a face stock material. 13.The RFID transponder of claim 1, wherein the RFID integrated circuitchip is disposed on the substrate.
 14. A RFID transponder comprising: asubstrate; an antenna structure formed on the substrate; and an RFIDintegrated circuit chip which is electrically coupled to the antennastructure, wherein the RFID integrated circuit chip is encoded with aglobal trade item number including a unique object number, the uniqueobject number comprising an object class information space including ablock of at least 50 bits and a unique serial number space including ablock of at least 38 bits, and wherein the unique serial number spacehas at least one allocated block stored therein defined by at least 3most significant bits of the unique serial number space as designated byan external numbering authority.
 15. The RFID transponder of claim 14,wherein remaining bits of lesser significance of the unique serialnumber space are encoded with a unique serial number for the objectclass.
 16. An integrated circuit, comprising: a radio frequency circuitconfigured to backscatter a return link signal for processing by an RFIDinterrogator; control logic; and a memory, wherein the memory isconfigured with a unique object number space, the unique object numberspace comprising an object class information space and a unique serialnumber space, and wherein the unique serial number space is encoded withan allocated block defined by a limited number of most significant bitsof the unique serial number space as designated by an external numberingauthority.
 17. The integrated circuit of claim 16, wherein remainingbits of lesser significance of the unique serial number space areencoded with a unique serial number for the object class.
 18. Theintegrated circuit of claim 16, wherein the object class informationspace is encoded with information comprising a company prefix, an itemreference, a partition value, and a filter value.
 19. The integratedcircuit of claim 16, wherein the unique object number is a portion of aserialized global trade item number.
 20. The integrated circuit of claim19, wherein the serialized global trade item number is an EPC SGTIN-96encoding.